GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu 🢒 Transmission/Transaxle 🢒 Automatic Transmission - 6T40/6T45 🢒 Transmission Replacement

Removal Procedure
  1. Remove the battery tray. Refer to Battery Tray Replacement.
  2. Remove the transmission range select lever cable and bracket. Refer to Range Selector Lever Cable Bracket Replacement.
  3. Drain the transmission fluid. Refer to Transmission Fluid Replacement.

    4. Object Number: 1999448 Size: SH
  4. Disconnect the control valve body transmission control module (TCM) electrical connector (1) then unclip the connector from the transmission.

    5. Object Number: 1998666 Size: SH
  5. Remove the oil cooler inlet (1) and outlet (5) hoses from the retainer (2) on the control valve body cover.
  6. Remove the transmission fluid cooler inlet hose nut (3) from the transmission.
  7. Remove the transmission fluid cooler inlet hose (1) from the transmission.
  8. Remove the transmission fluid cooler outlet hose nut (4) from the transmission.
  9. Remove the transmission fluid cooler outlet hose (5) from the transmission.
  10. Plug and/or cap the hose and transmission to prevent contamination.

    11. Object Number: 1998673 Size: SH
  11. Remove the upper transmission to engine bolts (2).
  12. Remove the frame. Refer to Frame Replacement.
  13. Disconnect the wheel drive shafts from the transmission. Refer to Wheel Drive Shaft Replacement.
  14. Remove the intermediate drive shaft. Refer to Intermediate Drive Shaft Replacement.
  15. Remove the rear transmission mount from the transmission. Refer to Transmission Mount Bracket Replacement - Rear.
  16. Remove the front transmission mount from the transmission. Refer to Transmission Front Mount Replacement.

    17. Object Number: 2001293 Size: SH
  17. Remove the starter. Refer to Starter Motor Replacement.
  18. Mark the relationship of the flywheel to the torque converter for reassembly.
  19. Remove the torque converter to flywheel bolts (1).
  20. Lower the vehicle.
  21. Remove the 3 left transmission mount bolts from the transmission. Refer to Transmission Mount Replacement - Left Side.
  22. Lower the transmission side with the support fixture to allow clearance for removal.
  23. Unclip the engine wiring harness from the transmission.
  24. Raise the vehicle.
  25. Use a transmission jack in order to support the transmission.

    26. Object Number: 1998673 Size: SH
  26. Remove the remaining transmission fasteners (1, 3, 4).

    27. Important: Insure the torque converter remains securely in place on the transmission input shaft while separating and removing the transmission.

  27. Separate the transmission from the engine.
  28. Lower the transmission with the transmission jack far enough to remove the transmission.

Installation Procedure
  1. Raise the transmission with the transmission jack and position the transmission to the engine.

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


    Object Number: 1998673 Size: SH
  2. Install the transmission bolts (1, 3, 4).

    3. Tighten
    Tighten the bolt to 75 N·m (55 lb ft).

  3. Remove the transmission jack.

    4. Object Number: 2001293 Size: SH

    Important: If reusing the torque converter bolts, clean the threads and apply LOCTITE™242, GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads prior to installation.

  4. Install the torque converter to flywheel bolts (1).

    5. Tighten
    Tighten the bolts to 62 N·m (46 lb ft).

  5. Install the starter. Refer to Starter Motor Replacement.
  6. Install the front transmission mount to the transmission. Refer to Transmission Front Mount Replacement.
  7. Install the rear transmission mount to the transmission. Refer to Transmission Mount Bracket Replacement - Rear.
  8. Install the intermediate drive shaft. Refer to Intermediate Drive Shaft Replacement.
  9. Install the wheel drive shafts to the transmission. Refer to Wheel Drive Shaft Replacement.
  10. Install the frame. Refer to Frame Replacement.

    11. Object Number: 1998673 Size: SH
  11. Install the upper transmission to engine bolts (2).

    12. Tighten
    Tighten the bolt to 75 N·m (55 lb ft).


    Object Number: 1998666 Size: SH
  12. Install the transmission fluid cooler outlet hose (5) to the transmission.
  13. Install the transmission fluid cooler outlet hose retainer nut (4).

    14. Tighten
    Tighten the nut to 22 N·m (16 lb ft).

  14. Install the transmission fluid cooler inlet hose (1) to the transmission.
  15. Install the transmission fluid cooler inlet hose retainer nut (3).
  16. Install the oil cooler inlet (1) and outlet (5) hoses to the retainer (2) on the control valve body cover.

    17. Object Number: 1999448 Size: SH
  17. Connect the control valve body TCM electrical connector (1).
  18. Install the transmission range select lever cable and bracket. Refer to Range Selector Lever Cable Bracket Replacement.
  19. Install the battery tray. Refer to Battery Tray Replacement.
  20. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable Adjustment.
  21. Fill the transmission with fluid. Refer to Transmission Fluid Replacement.
  22. For transmission control module programming and setup, refer to Control Module References.

    23. Important: After an internal transmission repair or internal part replacement the service fast learn adapt procedure should be performed.

  23. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts.
  24. Road test the vehicle.