GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2003 🢒 Sunfire 🢒 Transmission/Transaxle 🢒 Automatic Transaxle - 4T40-E/4T45-E 🢒 Control Valve Body Cover Replacement

Removal Procedure
  1. Remove the air inlet duct.

    2. Object Number: 893831 Size: SH
  2. Disconnect the shift cable from the PNP switch.
  3. Remove the shift cable lever.

    4. Object Number: 104504 Size: SH
  4. Remove the PNP switch. Refer to Park/Neutral Position Switch Replacement .
  5. Install the engine support fixture.
  6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  7. Remove the left front tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  8. Remove the left inner fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  9. Seperate the left ball joint from the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  10. Remove the wheel drive shaft from the transmission. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  11. Remove the power steering gear intermediate shaft pinch bolt.
  12. Remove the left front suspension cross member bolts. Refer to Crossmember Replacement in Frame and Underbody.
  13. Loosen the Right front suspension cross member bolts.

    14. Object Number: 510427 Size: SH
  14. Remove the transmission mount. Refer to Transmission Mount Replacement in Transmission/Transaxle.
  15. Lower the vehicle.
  16. Lower the engine with the engine support fixture.
  17. Raise the vehicle.
  18. Remove the transmission side cover bolts.
  19. Remove the transmission side cover.

Installation Procedure

    Object Number: 510427 Size: SH
  1. Install the transmission side cover.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Hand start the transmission side cover bolts.

    3. Tighten
    Tighten the side cover bolts and stud to 28 N·m (22 lb ft).

  3. Lower the vehicle.
  4. Raise the engine with the engine support fixture.
  5. Raise the vehicle.
  6. Install the transmission mount. Refer to Transmission Mount Replacement in Transmission/Transaxle.
  7. Install the front suspension cross member bolts. Refer to Crossmember Replacement in Frame and Underbody.
  8. Install the power steering gear intermediate shaft pinch bolt.

    9. Object Number: 104504 Size: SH
  9. Install the wheel drive shaft to the transmission. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  10. Connect the left ball joint to the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  11. Install the left inner fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  12. Install the left front tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  13. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  14. Remove the engine support fixture.
  15. Install the PNP switch. Refer to Park/Neutral Position Switch Replacement .

    16. Object Number: 893831 Size: SH
  16. Install the shift cable lever.
  17. Connect the shift cable from the PNP switch.
  18. Install the air inlet duct.
  19. Fill the transmission. Refer to Approximate Fluid Capacities in Maintenance and Lubrication.