GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - 4T65-E 🢒 Oil Pan Replacement

Removal Procedure

    Object Number: 164804 Size: SH

    Notice: Do NOT use any type of grease to retain parts during the assembly of this unit. Using greases other than the recommended assembly lube changes the transaxle fluid characteristics. Using greases other than the recommended assembly lube causes undesirable shift conditions and/or filter clogging. Use TRANSJEL™ J 36850 or equivalent during the assembly of this unit.

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Place a drain pan under the transaxle oil pan.
  3. Remove the transaxle oil pan bolts (23) from the front and the sides of the oil pan.
  4. Loosen the rear transaxle oil pan bolts.

    5. Notice: Ensure care is taken NOT to damage the mating surfaces of the oil pan and of the case or oil leaks may occur.

  5. Use a rubber mallet to lightly tap the oil pan or use a screwdriver to pry the oil pan loose.
  6. Allow the fluid to drain.
  7. Remove the remaining transaxle bolts (23).
  8. Remove the oil pan (24) from the automatic transmission.
  9. Remove the oil pan gasket (25).
  10. Inspect the oil pan and the filter for the following foreign material:
    11. • Metal particles
    • Clutch facing material
    • Rubber particles
    • Engine coolant
  11. Determine the source of the contamination.
  12. Correct the source of the contamination.

    13. Object Number: 164780 Size: SH
  13. Inspect the oil pan flange (1) for distortion.
  14. Replace the oil pan (1) if bent or distorted. Do not attempt to straighten.

    15. Object Number: 164805 Size: SH
  15. When service requires the removal of the bottom oil, inspect the washers on the oil pan bolts.

    16. Object Number: 164806 Size: SH
  16. If the washer is inverted, replace the bolt and the washer.

    17. Notice: Ensure the oil pan and the case flanges are dry and are free of any oil film or leakage may result.

  17. Use solvent to clean the case.
  18. Air dry the case.
  19. Use solvent to clean the oil pan gasket surfaces.
  20. Air dry the oil pan gasket surfaces.
  21. Remove all traces of the old gasket material.

Installation Procedure

    Object Number: 164804 Size: SH
  1. Install the oil pan gasket (25).
  2. Install the oil pan (24).

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the oil pan bolts (23).

    4. Tighten
    Tighten the bolts to 14 N·m (10 lb ft).

  4. Lower the vehicle.

    5. Notice: Refer to Transmission Overfill Notice in the Preface section.

  5. Fill the transaxle with DEXRON® VI. Refer to Fluid Capacity Specifications .
  6. Place the gear selector in the PARK position.
  7. Start the engine.
  8. Run the engine at a slow idle. Do NOT race the engine.
  9. Adjust the fluid level. Refer to Transmission Fluid Check .
  10. Inspect for leaks.