SECTION 5A

4T40-E AUTOMATIC TRANSAXLE

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.

TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-5 Valve Body-to-Spacer Plate Gasket . . . . . . . . . 5A-36
End Play Specifications . . . . . . . . . . . . . . . . . . . . 5A-5 Channel Plate Passages - Case Side . . . . . . . 5A-37
Transaxle General Specifications . . . . . . . . . . . . 5A-5 Case Passages - Channel Plate Side . . . . . . . 5A-38
Fluid Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-5 Case Passages - Bottom . . . . . . . . . . . . . . . . . . 5A-39
Range Reference . . . . . . . . . . . . . . . . . . . . . . . . . 5A-6 Spacer Plate-to-Channel Plate Gasket . . . . . . 5A-40
4T40-E Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . 5A-7 Channel Plate-to-Case Gasket . . . . . . . . . . . . . 5A-41
Shift Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-7 Spacer Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-42
Line Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-7 Pump Body Oil Channels . . . . . . . . . . . . . . . . . . 5A-43
Fastener Tightening Specifications . . . . . . . . . . . 5A-8 4T40-E Leak Inspection Points . . . . . . . . . . . . . 5A-44
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-9 Electronic Component Location Views . . . . . . . 5A-45
Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 5A-9 Control Valve Body Channels - Channel
Schematic and Routing Diagrams . . . . . . . . . . 5A-15 Plate Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-46
Transmission Control Module (1 of 3) . . . . . . . 5A-15 Control Valve Body Channels - Oil Pump
Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-47
Transmission Control Module (2 of 3) . . . . . . . 5A-16
Channel Plate Passages - Control Valve
Transmission Control Module (3 of 3) . . . . . . . 5A-17
Body Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-48
Visual Identification . . . . . . . . . . . . . . . . . . . . . . . 5A-18
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-49
Transaxle Identification Information . . . . . . . . . 5A-18
Basic Knowledge Required . . . . . . . . . . . . . . . . 5A-49
Component Locator . . . . . . . . . . . . . . . . . . . . . . . 5A-19
Functional Check Procedure . . . . . . . . . . . . . . . 5A-49
Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . 5A-19
4T40-E Transaxle Functional Check
Control Valve Body Assembly . . . . . . . . . . . . . . 5A-20 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-49
Driven Sprocket Support Line Pressure Check Procedure . . . . . . . . . . . . 5A-50
Assembly/2nd Clutch . . . . . . . . . . . . . . . . . . . 5A-21
Component Resistance Check Procedure . . . 5A-51
Reverse Input Clutch Assembly . . . . . . . . . . . . 5A-22
Pressure Switch Assembly Resistance
Direct and Coast Clutch Assemblies . . . . . . . . 5A-23 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-52
Reaction Carrier Assembly . . . . . . . . . . . . . . . . 5A-24 Clutch Plate Diagnosis . . . . . . . . . . . . . . . . . . . . 5A-53
Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . 5A-25 Engine Coolant in Transaxle . . . . . . . . . . . . . . . 5A-53
Input Internal Gear and Forward Cooler Flushing and Flow Test . . . . . . . . . . . . . 5A-54
Clutch Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-26
Fluid Leak Diagnosis and Repair . . . . . . . . . . . 5A-54
Forward Clutch Assembly . . . . . . . . . . . . . . . . . 5A-27
Case Porosity Repair . . . . . . . . . . . . . . . . . . . . . 5A-54
Forward Clutch Support Assembly . . . . . . . . . . 5A-28
4T40-E Fluid Level Service Procedure . . . . . . 5A-55
Final Drive and Differential Assembly . . . . . . . 5A-29
Electrical/Garage Shift Tests . . . . . . . . . . . . . . . 5A-56
Manual Shaft, Parking Panel and
Road Test Procedure . . . . . . . . . . . . . . . . . . . . . 5A-56
Actuator Assembly . . . . . . . . . . . . . . . . . . . . . 5A-30
Torque Converter Clutch Diagnosis . . . . . . . . . 5A-57
Case and Associated Parts (1 of 3) . . . . . . . . . 5A-31
Torque Converter Evaluation . . . . . . . . . . . . . . . 5A-58
Case and Associated Parts (2 of 3) . . . . . . . . . 5A-32
TCC Shudder Diagnosis . . . . . . . . . . . . . . . . . . . 5A-59
Case and Associated Parts (3 of 3) . . . . . . . . . 5A-34

DAEWOO J-100 BL2 / BL3

5A -- 2 4T40-E AUTOMATIC TRANSAXLE
Flexplate/Torque Converter Vibration DTC P0218 Transaxle Fluid
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 5A-59 Overtemperature . . . . . . . . . . . . . . . . . . . . . . . 5A-80
Hydra-Matic 4T40-E Shift Speed Chart . . . . . . 5A-60 DTC P0711 Transmission Fluid Temperature
Internal Wiring Harness Check . . . . . . . . . . . . . 5A-60 Sensor Circuit Range/Performance . . . . . . . 5A-82
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-62 DTC P0712 Transmission Fluid Temperature
Sensor Circuit Low Input . . . . . . . . . . . . . . . . 5A-86
4T40-E Component Resistance Chart . . . . . . . 5A-63
DTC P0713 Transmission Fluid Temperature
Automatic Transmission Fluid Pressure
Sensor Circuit High Input . . . . . . . . . . . . . . . . 5A-88
Manual Valve Position Switch
Resistance Check . . . . . . . . . . . . . . . . . . . . . . 5A-63 DTC P0716 Automatic Transmission
Input Speed Sensor Circuit
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 5A-65
Range/Performance . . . . . . . . . . . . . . . . . . . . 5A-90
High or Low Line Pressure . . . . . . . . . . . . . . . . . 5A-65
DTC P0717 Automatic Transmission
Inaccurate/Inconsistent Shift Points . . . . . . . . . 5A-65 Input Speed Sensor Circuit
Harsh Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-66 No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-92
No Reverse, Slips in Reverse . . . . . . . . . . . . . . 5A-66 DTC P0719 Brake Switch Circuit Low . . . . . . . 5A-94
No First Gear, Slips in First Gear . . . . . . . . . . . 5A-67 DTC P0722 Automatic Transmission Output
No Second Gear, Slips in Second Gear . . . . . 5A-67 Speed Sensor (A/T OSS) Low Input . . . . . . 5A-96
No Third Gear, Slips in Third Gear . . . . . . . . . . 5A-68 DTC P0723 Automatic Transmission Output
Speed Sensor (A/T OSS) Intermittent . . . . 5A-100
Second Gear Only . . . . . . . . . . . . . . . . . . . . . . . . 5A-68
DTC P0724 Brake Switch Circuit High . . . . . . 5A-104
No Fourth Gear, Slips in Fourth Gear . . . . . . . 5A-69
DTC P0726 Engine Speed Sensor Circuit
Loss of Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-69
Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-106
Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-70
DTC P0727 Engine Speed Sensor Circuit
Engine Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-70 Low Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-108
First and Second Gears Only . . . . . . . . . . . . . . 5A-70 DTC P0730 Incorrect Gear Ratio . . . . . . . . . . 5A-110
Third and Fourth Gears Only . . . . . . . . . . . . . . . 5A-70 DTC P0741 TCC Circuit Stuck Off . . . . . . . . . 5A-112
First and Fourth Gears Only . . . . . . . . . . . . . . . 5A-71 DTC P0742 TCC Circuit Stuck On . . . . . . . . . 5A-116
Second and Third Gears Only . . . . . . . . . . . . . . 5A-71 DTC P0748 PC Solenoid Circuit
No Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-71 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-120
Ratcheting Noise . . . . . . . . . . . . . . . . . . . . . . . . . 5A-71 DTC P0751 1-2 Shift Solenoid
No Engine Braking; All Manual Ranges . . . . . . 5A-72 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-124
No Engine Braking; Manual Second - DTC P0756 2-3 Shift Solenoid
Second Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-72 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-128
No Engine Braking; Manual First - DTC P1790 TCM Checksum Error . . . . . . . . . 5A-132
First Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-72 DTC P1810 Automatic Transmission Fluid
Drives in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . 5A-73 Pressure Manual Valve Position Switch
(TFP Val. Position Sw.) Malfunction . . . . . . 5A-134
No Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . 5A-73
DTC P1811 Maximum Adapt and
Shift Indicator Indicates Wrong Gear
Long Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-138
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-73
DTC P1814 Torque Converter
Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-73
Overstress . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-142
Fluid Foaming . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-73
DTC P1887 TCC Release Switch Circuit
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-74 Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-144
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-74 Maintenance and Repair . . . . . . . . . . . . . . . . . 5A-147
No TCC/Slipping/Soft Apply . . . . . . . . . . . . . . . . 5A-75 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 5A-147
No TCC Release . . . . . . . . . . . . . . . . . . . . . . . . . 5A-76 Transaxle Fluid Level Checking
TCC Apply With Cold Engine . . . . . . . . . . . . . . 5A-76 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-147
TCC Shudder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-76 Changing the Fluid . . . . . . . . . . . . . . . . . . . . . . 5A-148
Diagnostic Trouble Code Diagnosis . . . . . . . . 5A-77 Repairing Fluid Leaks . . . . . . . . . . . . . . . . . . . . 5A-148
Diagnostic Trouble Code (DTC) Case Porosity Repair . . . . . . . . . . . . . . . . . . . . 5A-149
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-77

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 3
Fluid Level Set After Service . . . . . . . . . . . . . . 5A-150 Drive, Driven Sprockets, Drive Link
Oil Cooler Flushing . . . . . . . . . . . . . . . . . . . . . . 5A-150 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-192
Shift Control Lever . . . . . . . . . . . . . . . . . . . . . . . 5A-151 Input Speed Sensor Removal . . . . . . . . . . . . . 5A-192
Shift Control Cable . . . . . . . . . . . . . . . . . . . . . . 5A-157 Wiring Harness Removal . . . . . . . . . . . . . . . . . 5A-193
Control Cable Adjustment . . . . . . . . . . . . . . . . 5A-160 Driven Sprocket Support Assembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-193
Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . 5A-161
2nd Clutch Plates Removal . . . . . . . . . . . . . . . 5A-193
Automatic Transmission Output Speed
Sensor (A/T OSS) . . . . . . . . . . . . . . . . . . . . . 5A-162 Reverse Input Clutch Housing
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-194
Pan, Gasket, and Filter . . . . . . . . . . . . . . . . . . . 5A-163
Intermediate 4th Band Removal . . . . . . . . . . . 5A-194
Reverse/Low Servo Assembly . . . . . . . . . . . . 5A-164
Direct/Coast Clutch and Reaction Gear
2nd/4th Servo Assembly . . . . . . . . . . . . . . . . . 5A-165
Set Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-194
Case Side Cover Pan and Gaskets . . . . . . . . 5A-165
Input Carrier and Reaction Gear
1-2 Shift Solenoid . . . . . . . . . . . . . . . . . . . . . . . 5A-167 Assembly Removal . . . . . . . . . . . . . . . . . . . . 5A-195
2-3 Shift Solenoid . . . . . . . . . . . . . . . . . . . . . . . 5A-167 Input Internal Gear, Forward Clutch
Pressure Control Solenoid . . . . . . . . . . . . . . . . 5A-168 Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5A-195
TCC Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-169 Forward Clutch and Low/Reverse Band
Drive Axle Oil Seal . . . . . . . . . . . . . . . . . . . . . . 5A-169 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-195
Oil Cooler Pipes . . . . . . . . . . . . . . . . . . . . . . . . . 5A-170 Forward Clutch Support, Low Roller
Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . 5A-196
Oil Cooler Hoses and Pipe . . . . . . . . . . . . . . . . 5A-171
Output Shaft and Final Drive Assembly
Transaxle Mount . . . . . . . . . . . . . . . . . . . . . . . . 5A-173
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-197
Transaxle Bracket . . . . . . . . . . . . . . . . . . . . . . . 5A-175
Final Drive Internal Gear Removal . . . . . . . . . 5A-197
Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . 5A-176
Manual Shaft, Detent Lever, Park Lock
Transaxle Brace . . . . . . . . . . . . . . . . . . . . . . . . . 5A-183 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-197
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-185 Transaxle Cooler Line Seal Removal . . . . . . . 5A-198
Torque Converter Removal . . . . . . . . . . . . . . . 5A-185 Torque Converter Seal Removal . . . . . . . . . . . 5A-198
Transaxle Holding Fixture Assembly . . . . . . . 5A-185 Drive Sprocket Support Removal . . . . . . . . . . 5A-198
Stub Shaft Removal . . . . . . . . . . . . . . . . . . . . . 5A-186 Right Hand Axle Seal Removal . . . . . . . . . . . . 5A-199
Automatic Transmission Output Speed Case Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 5A-199
Sensor Removal . . . . . . . . . . . . . . . . . . . . . . 5A-186
Actuator Guide Replacement . . . . . . . . . . . . . 5A-200
Oil Pan and Gasket Removal . . . . . . . . . . . . . 5A-187
Drive Sprocket Support Installation . . . . . . . . 5A-200
Oil Filter/Seal, Oil Level Control Valve
Torque Converter Seal Installation . . . . . . . . . 5A-201
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-187
Transaxle Cooler Line Seals Installation . . . . 5A-201
Oil Feed Pipes Removal . . . . . . . . . . . . . . . . . . 5A-187
Manual Shaft, Detent Lever, Park Lock
Inter 4th Servo Removal . . . . . . . . . . . . . . . . . . 5A-188
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-201
Low/Reverse Servo Removal . . . . . . . . . . . . . 5A-188
Final Drive Assembly Disassemble . . . . . . . . 5A-202
Case Side Cover Removal . . . . . . . . . . . . . . . . 5A-188
Final Drive Assembly Assemble . . . . . . . . . . . 5A-205
Oil Pump and Oil Pump Shaft Removal . . . . . 5A-189
Final Drive Pinion End Play Check . . . . . . . . . 5A-206
Wire Harness Disconnect . . . . . . . . . . . . . . . . . 5A-189
Fretting Ring, Final Drive Internal
Pressure Switch Assembly Removal . . . . . . . 5A-189 Gear Install . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-207
Control Valve Body Assembly and Gasket Final Drive and Differential Assembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-190 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-207
Spacer Plate and Gasket Removal . . . . . . . . 5A-190 Forward Clutch Support, Roller Clutch
Checkball Removal . . . . . . . . . . . . . . . . . . . . . . 5A-190 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-207
Manual Valve Clip Removal . . . . . . . . . . . . . . . 5A-191 Forward Clutch Support, Low Roller
Channel Plate and Gasket Removal . . . . . . . 5A-191 Clutch Assemble . . . . . . . . . . . . . . . . . . . . . . 5A-209
Accumulator Spring Removal . . . . . . . . . . . . . 5A-191 Forward Clutch Support, Low Roller
Clutch Install . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-210
Output Shaft Sleeve Removal . . . . . . . . . . . . . 5A-192

DAEWOO J-100 BL2 / BL3

5A -- 4 4T40-E AUTOMATIC TRANSAXLE
Forward Clutch Disassemble . . . . . . . . . . . . . . 5A-210 Drive, Driven Sprockets and Drive Link
Forward Clutch Assemble . . . . . . . . . . . . . . . . 5A-212 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-244
Forward Clutch Functional Air Check . . . . . . . 5A-213 Channel Plate Assembly Disassemble . . . . . 5A-244
Low/Reverse Band Install . . . . . . . . . . . . . . . . 5A-214 Channel Plate Assembly Assemble . . . . . . . . 5A-245
Forward Clutch Installation . . . . . . . . . . . . . . . 5A-214 Accumulator Springs Install . . . . . . . . . . . . . . . 5A-245
Input Internal Gear, Forward Clutch Channel Plate Assembly Installation . . . . . . . 5A-246
Hub Disassemble . . . . . . . . . . . . . . . . . . . . . 5A-215 Manual Valve Install . . . . . . . . . . . . . . . . . . . . . 5A-246
Input Internal Gear, Forward Clutch Checkballs Installation . . . . . . . . . . . . . . . . . . . 5A-247
Hub Assemble . . . . . . . . . . . . . . . . . . . . . . . . 5A-215 Spacer Plate and Gaskets Install . . . . . . . . . . 5A-247
Input Internal Gear, Forward Clutch Control Valve Body Disassemble . . . . . . . . . . 5A-248
Hub Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-216
Control Valve Body Assemble . . . . . . . . . . . . . 5A-252
Reaction Internal Gear, Input Carrier
Control Valve Assembly and TFP Switch
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-216
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-256
Input Carrier Pinion Gear Clearance
Wiring Harness Assembly Connect . . . . . . . . 5A-257
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-216
Oil Pump Clean and Inspect . . . . . . . . . . . . . . 5A-258
Reaction Internal Gear, Input Carrier
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-217 Oil Pump Assembly Installation . . . . . . . . . . . . 5A-258
Reaction Internal Gear, Input Carrier Side Cover/Gaskets, Disassemble,
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-217 Assemble, Install . . . . . . . . . . . . . . . . . . . . . . 5A-258
Direct/Coast Clutch, Reaction Carrier Output Shaft Sleeve Assemble . . . . . . . . . . . . 5A-260
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-217 Output Shaft and Sleeve Assembly
Reaction Carrier Pinion Clearance Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-261
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-222 Side Cover Axle Seal Install . . . . . . . . . . . . . . 5A-261
Direct/Coast Clutch, Reaction Carrier Stub Shaft Sleeve Assemble and Install . . . . 5A-262
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-223 Right Hand Axle Seal Assemble . . . . . . . . . . . 5A-262
Direct and Coast Clutch Functional Air Output Speed Sensor Installation . . . . . . . . . . 5A-263
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-228
Inter 4th Servo Disassemble, Assemble,
Direct/Coast Clutch, Reaction Carrier and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-263
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-228
Low/Reverse Servo Assembly
Selective Washer Measurement and Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-265
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-229
Low/Reverse Servo Assembly
Reverse Input and 2nd Roller Clutch Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-265
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-229
Oil Feed Pipes Assemble . . . . . . . . . . . . . . . . . 5A-265
Reverse Input and 2nd Roller Clutch
Filter Assembly and Seal Install . . . . . . . . . . . 5A-266
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-232
Oil Level Control Valve Install . . . . . . . . . . . . . 5A-267
Reverse Clutch Functional Air Check . . . . . . . 5A-233
Oil Pan and Gasket Install . . . . . . . . . . . . . . . . 5A-267
Reverse Input and 2nd Roller Clutch
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-235 Torque Converter Installation . . . . . . . . . . . . . . 5A-268
Intermediate 4th Band Assembly Install . . . . 5A-235 General Description and System
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-269
2nd Clutch Plate Installation . . . . . . . . . . . . . . 5A-236
Transaxle Definitions and Abbreviations . . . . 5A-269
Driven Sprocket Assembly Disassemble . . . . 5A-236
Transaxle General Description . . . . . . . . . . . . 5A-270
Drive Sprocket Support Assemble . . . . . . . . . 5A-239
Transaxle Component and System
2nd Clutch Functional Air Check . . . . . . . . . . . 5A-240
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-270
Driven Sprocket Support Assembly
Range Reference Chart . . . . . . . . . . . . . . . . . . 5A-272
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-240
Automatic Transmission Output (Shaft)
Wiring Harness Installation . . . . . . . . . . . . . . . 5A-241
Speed Sensor (A/T OSS) . . . . . . . . . . . . . . . 5A-273
Input Speed Sensor Install . . . . . . . . . . . . . . . . 5A-241
Automatic Transmission Input (Shaft)
Drive, Driven Sprockets and Drive Link Speed Sensor (A/T ISS) . . . . . . . . . . . . . . . . 5A-273
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-242
Shift Solenoids: 1-2 and 2-3 . . . . . . . . . . . . . . 5A-273
Drive, Driven Sprockets and Drive Link
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-243

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 5
Pressure Control Solenoid Valve Park (Engine Running) . . . . . . . . . . . . . . . . . . . 5A-280
(PC Sol. Valve) . . . . . . . . . . . . . . . . . . . . . . . . 5A-274 Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-282
Torque Converter Clutch Solenoid Valve Neutral (Engine Running) . . . . . . . . . . . . . . . . . 5A-284
(TCC Sol. Valve) . . . . . . . . . . . . . . . . . . . . . . 5A-275
Overdrive Range - First Gear . . . . . . . . . . . . . 5A-286
Automatic Transmission Fluid Pressure
Overdrive Range - Second Gear . . . . . . . . . . 5A-288
Manual Valve Position Switch
(TFP Val. Position Sw.) . . . . . . . . . . . . . . . . . 5A-275 Overdrive Range - Third Gear . . . . . . . . . . . . 5A-290
Transmission Fluid Temperature (TFT) Overdrive Range - Fourth Gear . . . . . . . . . . . 5A-292
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-276 Overdrive Range - 4-3 Downshift . . . . . . . . . . 5A-294
Transmission Electrical Connector . . . . . . . . . 5A-277 Manual Third - Third Gear . . . . . . . . . . . . . . . . 5A-296
Transmission Control Module (TCM) . . . . . . . 5A-278 Manual Second - Second Gear . . . . . . . . . . . 5A-298
Data Link Connector (DLC) . . . . . . . . . . . . . . . 5A-278 Manual First - First Gear . . . . . . . . . . . . . . . . . 5A-300
TCM Inputs That Affect the 4T40-E
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . 5A-278

SPECIFICATIONS
END PLAY SPECIFICATIONS
Dimension A (mm) Washer Selection Washer Dimension
100.40-100.70 Brown 1.50-1.60
100.70-100.99 Grey 1.80-1.90
100.99-101.29 Natural 2.09-2.19
101.29-101.59 Black 2.39-2.49
101.59-101.88 Orange 2.68-2.78
101.88-102.18 Violet 2.98-3.08
102.18-102.48 Yellow 3.28-3.38
102.48-102.77 Red 3.57-3.67
102.77-103.07 Green 3.87-3.97

TRANSAXLE GENERAL SPECIFICATIONS

Dimension A (mm) Backing Plate Identification
8.970-9.433 A
9.434-10.007 B
10.008-10.470 C

FLUID CAPACITY
Litres Quarts
Bottom Pan Removal 6.5 6.9
Complete Overhaul 9.0 9.5
Dry 12.2 12.9
(Measurements are approximate)

DAEWOO J-100 BL2 / BL3

5A -- 6 4T40-E AUTOMATIC TRANSAXLE

RANGE REFERENCE
Park/
Range Neutral Reverse D 3 2 1
Gear N R 1st 2nd 3rd 4th 1st 2nd 3rd 1st 2nd 3rd** 1st 2nd**
*
1-2 Shift
Solenoid ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF ON OFF
2-3 Shift
Solenoid OFF OFF OFF OFF ON ON OFF OFF ON OFF OFF ON OFF OFF
2nd
Clutch -- -- -- A A* A* - A A* - A A* -- A
2nd Roller
Clutch -- -- -- H O - - H O - H O -- H
Int./4th
Band -- -- -- -- - A - - - - A - -- A
Reverse
Clutch -- A -- -- - - - - - - - - -- --
Coast
Clutch -- -- -- -- - - A A A A A A A A
Input
Sprag -- -- H H H O H H H H H H H H
Direct
Clutch -- -- -- -- A A - - A - - A -- --
Forward
Clutch -- -- A A A A* A A A A A A A A
LO/Rev
Band A A -- -- - - - - - - - - A --
LO Roller
Clutch -- -- H O O O H O O H O O H O
A =Applied
H =Holding
O =Overrunnig
ON =The solenoid is energized.
OFF =The solenoid is de-energized.
* =Applied with no load.
** =Manual Second--Third gear is only available above approximately 100 km/h (62 mph).
*** =Manual First--Second gear is only available above approximately 60 km/h (37 mph).
NOTE: Manual First--Third gear is also possible at high vehicle speed as a safety feature.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 7

4T40-E GEAR RATIOS

Gear Ratio
First 2.96
Second 1.62
Third 1.00
Fourth 0.68
Reverse 2.14

SHIFT SPEED
1-2 Shift @ +/- 3 2-3 Shift @ +/- 4 3-4 Shift @ +/- 5 TCC
Downshift @ +/- 4 mph
% of TPS mph mph mph Apply
43
4-3 32
3-2 21
2-1 4th
Model Series 10 25 50 10 25 50 10 25 50 Coast Coast Coast Gear
WKR J 9 14.5 20 17 25 39.5 30 36 57 26 11.5 6 42
WBR J 9 15 27 17 28 51 38 40 78 30 13 7 36

LINE PRESSURE
Pressure Control Solenoid Current Approximate Line Pressure
(Amp) (psi)
0.00 152-160
0.10 149-151
0.30 141-143
0.50 124-127
0.60 111-115
0.70 97-101
0.80 81-84
0.90 64-67
0.95 56-58
1.00 50-51
1.05 50
1.10 50

DAEWOO J-100 BL2 / BL3

5A -- 8 4T40-E AUTOMATIC TRANSAXLE

FASTENER TIGHTENING SPECIFICATIONS

Application NSm Lb-Ft Lb-In
A/T OSS Stud 12 - 106
Bell Housing Bolts 75 55 -
Channel Plate-to-Case Bolt 12 9 -
Channel Plate-to-Case Valve Body Bolts 12 - 106
Channel Plate-to-Case Valve Body Pressure Switch Manual 12 - 106
Bolts
Channel Plate-to-Case Valve Body Pump Bolts 12 - 106
Channel Plate-to-Support-Driven Sprocket Bolt 14 10.5 -
Channel Plate-to-Support-Driven Sprocket Spacer Bolts 14 10.5 -
Channel Plate Valve Body Pressure Switch Manual Bolts 12 - 106
Detent-to-Channel Plate Spring & Roller Assembly 12 - 106
Drive Sprocket-to-Case Support Assembly Bolts 12 9 -
Engine Mounting Bolts 75 55 -
Flex Plate-to-Torque Converter Attachment Bolts 62 46 -
Floor Bracket Bolt 8 - 71
Fluid Level Plug 12 - 106
Flywheel Bolts 65 48 -
Frame Bolts 75 55 -
Input Speed Sensor Bolt 12 - 106
Oil Cooler Pipe Bolt 22 16 -
Oil Cooler Pipe Bracket Bolt 25 18 -
Oil Pipe Bolts 12 9 -
Pivot Bolt 58 43 -
Servo Cover Bolts 12 - 106
Shift Control Assembly Bolts -
Shift Control Cable Adjuster Pinch Bolt Nut 8 - 71
Shift Control Cable Attachment Nut 6 - 53
Shift Control Cable Mounting Bracket Nuts 6 - 53
Shift Control Lever Bolt -
Side Cover Bolts 20 15 -
Side-to-Case (Stud) Cover 20 15 -
Speed Sensor Stud 12 9 -
Transaxle Brace Mounting Bolts 75 55 -
Transaxle Mount Bolts 81 60 -
Transaxle Mount Upper Attachment Nut 169 125 -
Transaxle Mounting Bracket Bolt 61 45 -
Transaxle Pan Bolts 12 - 106
Trans Oil-to-Cover LO/Reverse Servo Tube Assembly 12 - 106
Trans Oil-to-Support Forward Clutch Tube Assembly 12 - 106
Valve Body-to-Channel Plate Bolts 12 - 106
Valve Body-to-Channel Plate Pump Bolts 12 - 106
Wiring Harness Clip 12 9 -

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 9

SPECIAL TOOLS
SPECIAL TOOLS TABLE

J 33095
Control Module
Connector Terminal
Remover

A103A265

Scan Tool

J 34142-B
Universal Test Lamp

A103A262 A103A266

J 21867 J 35616
Universal Pressure Connector Test
Gauge Set Adapter Kit

A103A263 A103A267

J 28742-A J 35689-A
Weather Pack Metri-pack Terminal
Terminal Remover Remover

A103A264 A103A268

DAEWOO J-100 BL2 / BL3

5A -- 10 4T40-E AUTOMATIC TRANSAXLE

SPECIAL TOOLS TABLE (Cont’d)

J 3289-20
J 36169-A
Transmission Holding
Fused Jumper Wire
Fixture Base

A103A269 A103A273

J 41230
J 38125-4
Transmission Holding
Terminal Repair Kit
Fixture

A103A270 A103A274

J 39200
J 6125-1B
Digital Volt-Ohmmeter
Slide Hammer
(DVOM)

A103A271 A103A275

J 38868
J 39775
Stub Shaft
Jumper Harness
Sleeve Remover

A103A272 A103A276

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 11

SPECIAL TOOLS TABLE (Cont’d)

J 41227 J 41239-2
Output Shaft Cooler Line Seal
Sleeve Remover Remover

A103A277 A103A281

J 41101 J 28540-A
Pass Through Torque Converter
Connector Remover Seal Installer

A103A278 A103A282

J 28585
J 36850
Snap Ring
Assembly Lubricant
Screwdriver

A103A279 A103A283

J 41239-1
J 41102
Cooler Line
Axle Seal Installer
Seal Installer

A103A280 A103A284

DAEWOO J-100 BL2 / BL3

5A -- 12 4T40-E AUTOMATIC TRANSAXLE

SPECIAL TOOLS TABLE (Cont’d)

J 41229 J 41228
Manual Shaft to Stub Shaft
Case Pin Sleeve Installer

A103A285 A103A289

J 25031-A
J 23327
Forward and Reverse
Clutch Spring
Clutch Inner Seal
Compressor
Assembly Remover

A103A286 A103A290

J 41236
J 41097-2
Coast Clutch Return
Inner Seal Assembly
Spring Compressor
Remover - Disc
Adapter

A103A287 A103A291

J 41232
J 41231
Direct Reverse,
Forward Clutch
Second Clutch
Inner Seal Assembly
Return Spring
Installer
Compressor Adapter

A103A288 A103A292

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 13

SPECIAL TOOLS TABLE (Cont’d)

J 41234-1 J 41233
Input Shaft Seal Reverse Clutch
Installer Pusher Inner Seal Installer

A103A293 A103A297

J 41234-2
Input Shaft Seal J 41235
Installer Protector Second Roller
Clutch Installer

A103A294 A103A298

J 41234-3 J 29569-1/J 29829-1

Input Shaft Seal Turbine Shaft Seal
Installer Sizer Installer

A103A295 A103A299

J 34673 J 29569-2/J 29829-2

Input Shaft End Turbine Shaft
Play Gauge Block Seal Sizer

A103A296 A103A300

DAEWOO J-100 BL2 / BL3

5A -- 14 4T40-E AUTOMATIC TRANSAXLE

SPECIAL TOOLS TABLE (Cont’d)

J 21366 J 28467-B
Torque Converter Engine Support
Holding Strap Fixture

A103A301 A102B152

J 41103
Torque Converter
Seal Remover Set

A103A302

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 15

SCHEMATIC AND ROUTING DIAGRAMS

TRANSMISSION CONTROL MODULE (1 OF 3)

B203A001

DAEWOO J-100 BL2 / BL3

 5A -- 16 4T40-E AUTOMATIC TRANSAXLE
TRANSMISSION CONTROL MODULE (2 OF 3)

B203A002

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 17
TRANSMISSION CONTROL MODULE (3 OF 3)

B203A003

DAEWOO J-100 BL2 / BL3

5A -- 18 4T40-E AUTOMATIC TRANSAXLE

VISUAL IDENTIFICATION
TRANSAXLE IDENTIFICATION INFORMATION

A103A001

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 19

COMPONENT LOCATOR
OIL PUMP ASSEMBLY

A103A003

200 Oil Pump Bearing and Seal Assembly 208 Oil Pump Slide Seal
201 Oil Pump Base 209 O-Ring (Oil Pump Slide) Seal
202 Oil Pump Vane Ring 210 Fluid Seal (Slide-to-Body) Ring
203 Oil Pump Vane 212 Oil Pump Priming Spring
204 Oil Pump Rotor 213 Locating Pin
205 Pivot (Oil Pump Slide Pin) 214 Pressure Relief Ball
206 Oil Pump Slide 215 Pressure Relief Spring
207 Oil Pump Slide Seal Support 216 Oil Pump Body
217 Pump Cover

DAEWOO J-100 BL2 / BL3

5A -- 20 4T40-E AUTOMATIC TRANSAXLE

CONTROL VALVE BODY ASSEMBLY

A103A004

300 Control Valve Assembly Body 315 Actuator Feed Limit Valve
301 1-2 Shift Valve Spring 316 Actuator Feed Limit Valve Spring
302 1-2 Shift Valve 317 Bore Plug
303 Shift Solenoid A and B O-Ring 318 3-4 Shift Valve Spring
304 Retainer Clip 319 3-4 Shift Valve
305 Shift (A and B) Solenoid 320 3-4 Shift Valve Plug O-Ring
306 2-3 Shift Valve Spring 321 Bore Plug
307 2-3 Shift Valve 323 1-2/3-4 Accumulator Valve
308 Torque Signal Regulator Valve Spring 324 Pressure Regulator Boost Bushing
309 Torque Signal Regulator Valve 325 Pressure Regulator Boost Valve
310 Pressure Control Solenoid O-Ring 326 Isolator Spring
311 Pressure Control Solenoid O-Ring 327 Pressure Regulator Valve Spring
312 Pressure Control Solenoid 328 Pressure Regulator Valve
313 Actuator Oil Filter O-Ring 329 2-3 Accumulator Valve Spring
314 Actuator Oil Filter 330 2-3 Accumulator Valve

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 21

331 TCC Feed Limit Valve Spring 337 TCC Control Solenoid O-Ring
332 TCC Feed Limit Spring 338 TCC Control Solenoid O-Ring
333 TCC Control Valve Spring 339 TCC-Regulated Apply Valve
334 TCC Control Valve 340 TCC-Regulated Apply Valve Spring
335 TCC Control Solenoid

DRIVEN SPROCKET SUPPORT ASSEMBLY/2ND CLUTCH

A103A005

400 Driven Sprocket Support Bearing 404 2nd Clutch Piston Assembly
401 Driven Sprocket Support 405 2nd Clutch Spring Assembly
402 Driven Sprocket Support Bushing 406 2nd Clutch Spring Retaining Ring
403 Oil Seal Ring 407 Reverse Intermediate Clutch Housing Valve
Assembly

DAEWOO J-100 BL2 / BL3

5A -- 22 4T40-E AUTOMATIC TRANSAXLE

REVERSE INPUT CLUTCH ASSEMBLY

A103A006

450 2nd Roller Clutch Retainer 457 Reverse Clutch Piston Assembly
451 2nd Roller Clutch Cam 458 Reverse Clutch Spring and Retainer Assembly
452 2nd Roller Clutch Assembly 459 Snap (Reverse Clutch Spring Retainer) Ring
453 Reverse Clutch Bushing 460 Reverse Clutch (Waved) Plate
454 Reverse Clutch Housing 461 Reverse Clutch (Steel) Plate
455 Reverse Clutch Bushing 462 Reverse Clutch (Fiber) Plate
456 Reverse Clutch Center Retainer and Seal 463 Reverse Clutch (Backing) Selective Plate
Assembly 464 Snap (Reverse Clutch) Ring

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 23

DIRECT AND COAST CLUTCH ASSEMBLIES

A103A007

500 Oil Seal - Input Shaft Ring 518 Direct Clutch Piston Assembly
501 Input Shaft Bushing 519 Direct Clutch Spring and Retainer Assembly
502 Direct and Coast Clutch and Input Shaft 520 Direct Clutch Spring Retainer Ring
503 Direct Clutch Housing-to-Output Shaft 521 Direct Clutch (Steel) Plate
504 Coast Clutch Piston Assembly 522 Direct Clutch (Fiber) Plate
505 Coast Clutch Release Spring 523 Direct Clutch (Backing) Plate
506 Coast Clutch Spring Retainer 524 Thrust Bearing
507 Snap (Coast Clutch Spring Retainer) Ring 525 Reaction Carrier Shaft Bushing
508 Coast Clutch (Steel) Plate 526 Reaction Carrier Shaft Shell
509 Coast Clutch (Fiber) Plate 527 Thrust (Carrier Shaft-to-Shell) Bearing
510 Thrust Bearing 528 Reaction Sun Gear Bushing
511 Input Sun Gear Shaft and Inner Race Assembly 529 Reaction Sun Shell
512 Outer (Input Sprag) Race 531 Reaction Carrier Assembly
514 Sprag Clutch (2) End Bearings 532 Thrust (Reaction Carrier-to-Sun Gear) Bearing
515 Input Sprag Assembly 533 Input Sun Gear
516 Snap (Outer Race-to-Sprag Assembly) Ring 534 Snap Ring
517 Snap (Direct/Coast Clutch Retaining) Ring

DAEWOO J-100 BL2 / BL3

5A -- 24 4T40-E AUTOMATIC TRANSAXLE

REACTION CARRIER ASSEMBLY

A103A008

550 Reaction Carrier 554 Pinion Thrust Inner Washer

551 Thrust Bearing 555 Roller Needle Bearing
552 Planet Pinion Pin 556 Reaction Planet Pinion
553 Pinion Thrust Reaction Washer

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 25

INPUT CARRIER ASSEMBLY

A103A009

560 Internal (Input and Reaction) Gear 565 Pinion Thrust Input Washer
561 Thrust Bearing 566 Pinion Thrust Inner Washer
562 Input Carrier 567 Roller Needle Bearing
563 Snap (Input Carrier-to-Internal Gear) Ring 568 Pinion Gear
564 Planet Pinion Pin

DAEWOO J-100 BL2 / BL3

5A -- 26 4T40-E AUTOMATIC TRANSAXLE

INPUT INTERNAL GEAR AND FORWARD CLUTCH HUB

A103A010

560 Internal (Input and Reaction) Gear 577 Input Flange and Forward Clutch Hub
575 Input Flange Bushing 554 Snap (Input Internal Gear-to-Input Flange) Ring

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 27

FORWARD CLUTCH ASSEMBLY

A103A011

600 Snap (Forward Clutch) Ring 606 Forward Clutch Return Spring Assembly
601 Forward Clutch (Backing) Plate 607 Forward Clutch Piston Assembly
602 Forward Clutch (Fiber) Plate 608 Forward Clutch Inner Seal and Sleeve
603 Forward Clutch (Steel) Plate Assembly
604 Forward Clutch (Waved) Plate 609 Forward Clutch Housing
605 Snap (Forward Clutch Spring Assembly) 610 Forward Clutch Support Bushing
Ring 611 Forward Clutch Support Bushing

DAEWOO J-100 BL2 / BL3

5A -- 28 4T40-E AUTOMATIC TRANSAXLE

FORWARD CLUTCH SUPPORT ASSEMBLY

A103A012

650 Final Drive Sun Shaft Bushing 659 Park Lock Gear
651 Final Drive Sun Shaft 660 Snap (Final Drive Sun Shaft) Ring
652 Lo Roller Clutch Assembly 661 Parking Lock Pawl Shaft
654 Oil Seal (Forward Clutch Support) Ring 662 Parking Lock Pawl Return Spring
656 Forward Clutch Support 663 Parking Lock Pawl
658 Thrust (Forward Support-to-Park Gear)
Bearing

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 29

FINAL DRIVE AND DIFFERENTIAL ASSEMBLY

A103A013

700 Thrust Bearing 707 Differential Pinion Gear

701 Spiral Pin Retaining Ring 708 Thrust Differential Side Gear Washer
702 Differential and Final Drive Carrier 709 Differential Slide Gear
703 Differential Pinion Shaft 710 Pinion Thrust Washer
704 Differential Pinion Shaft Retaining Pin 711 Pinion (Final Drive Planet) Gear
705 Speed Sensor Rotor 712 Roller Needle Bearing
706 Thrust (Differential Pinion) Washer 713 Pinion Needle Bearing Spacer
714 Pin, Planet Pinion Gear

DAEWOO J-100 BL2 / BL3

5A -- 30 4T40-E AUTOMATIC TRANSAXLE

MANUAL SHAFT, PARKING PANEL AND ACTUATOR ASSEMBLY

A103A014

800 Manual Valve 806 Manual Shaft and Detent Lever Assembly
801 Manual Valve-to-Link Clip 807 Parking Lock Actuator Assembly
802 Manual Valve-to-Detent Lever Link 809 Manual Shaft-to-Case Seal
803 Manual Shaft-to-Case Pin 810 Spring (Actuator Guide) Pin
804 Manual Detent Spring and Roller Assembly 811 Actuator Guide Seal
805 Spring and Roller Assembly-to-Channel Plate 812 Actuator Guide
Bolt

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 31

CASE AND ASSOCIATED PARTS (1 OF 3)

A103A015

1 Side Cover (Structural) 51 Transmission Case

2 Axle Oil Seal 52 Vent Cap
3 Side Cover Bolt 55 Torque Converter Assembly
4 Side Cover Stud 61 Output Speed Sensor Stud
5 Side Cover Gasket 62 Output Speed Sensor
6 Side Cover Oil Level Control Gasket 63 O-Ring (Output Speed Sensor) Seal
7 Thrust (Side Cover-to-Driven Sprocket) Washer 64 Band Anchor-LO/Reverse Pin
8 Oil Pump Bolt 65 Oil Level Control Plug
9 Oil Pump Bolt 81 Tube Assembly Bolt/Bottom Pan Bolt
10 Transmission Oil Pump Assembly 84 Transmission Oil Filter Seal
11 Transmission Wiring Harness 85 Transmission Oil Filter Assembly
12 Transmission Fluid Pressure Switch Bolt 86 Oil Level Control Valve
13 Transmission Fluid Pressure (TFP) Switch 87 Transmission Bottom Pan Gasket
15 Wiring Harness Bracket Bolt/Input Speed 88 Transmission Oil Pan
Sensor Bolt 89 Chip Collector Magnet

DAEWOO J-100 BL2 / BL3

5A -- 32 4T40-E AUTOMATIC TRANSAXLE

CASE AND ASSOCIATED PARTS (2 OF 3)

A103A016

16 Valve Body Bolt 29A Accumulator Piston (1-2, 2-3, and 3-4)
17 Filter 29B Accumulator Piston (1-2, 2-3, and 3-4)
18 Control Valve Body Assembly 29C Accumulator Piston (1-2, 2-3, and 3-4)
19 Oil Pump Drive Shaft 30A Accumulator Piston Seal (1-2, 2-3 and 3-4)
20 Spacer Plate Support Bolt 30B Accumulator Piston Seal (1-2, 2-3 and 3-4)
21 Spacer Plate Support 30C Accumulator Piston Seal (1-2, 2-3 and 3-4)
22 Valve Body-to-Spacer Plate Gasket 31 1-2 Accumulator Piston Spring
23 Valve Body Spacer Plate 32A 2-3 and 3-4 Accumulator Piston Spring
24 Spacer Plate-to-Channel Plate Gasket 32B 2-3 and 3-4 Accumulator Piston Spring
25A Channel Plate Bolt/Servo Cover Bolt 45 Dowel (Channel Plate-to-Case) Pin
25B Channel Plate Bolt/Servo Cover Bolt 48 Line Pressure Tap Plug
25C Channel Plate Bolt/Servo Cover Bolt 49 Cooler Pipe Seal
26 Checkballs 51 Transmission Case
27 Channel Plate 66 Servo Return (LO/Reverse) Spring
28 Case-to-Channel Plate Gasket 67 Servo Apply (LO/Reverse) Pin

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 33

68A Servo Cushion Spring 78 Servo Piston (Intermediate/4th) Seal

68B Servo Cushion Spring 79 Servo Cover (Intermediate/4th) Seal
69 Servo (LO/Reverse) Piston 80 Servo (Intermediate/4th) Cover
70A Servo Snap Ring 81A Tube Assembly Bolt/Bottom Pan Bolt
70B Servo Snap Ring 81B Tube Assembly Bolt/Bottom Pan Bolt
71 Servo Piston (LO/Reverse) Seal 81C Tube Assembly Bolt/Bottom Pan Bolt
72 Servo Cover (LO/Reverse) Seal 82A Oil Feed Tube Assembly Seal
73 Servo (LO/Reverse) Cover 82B Oil Feed Tube Assembly Seal
75 Servo Return (Intermediate/4th) Spring 82C Oil Feed Tube Assembly Seal
76 Servo Apply (Intermediate/4th) Pin 82D Oil Feed Tube Assembly Seal
77 Servo (Intermediate/4th) Piston 83 Oil Feed Tube Assembly

DAEWOO J-100 BL2 / BL3

5A -- 34 4T40-E AUTOMATIC TRANSAXLE

CASE AND ASSOCIATED PARTS (3 OF 3)

A103A017

2 Axle Oil Seal 46 Input Speed Sensor

15 Wiring Harness Bracket Bolt/Input Speed 48 Line Pressure Tap Plug
Sensor Bolt 49 Cooler Pipe Seal
33 Turbine Shaft-to-Drive Sprocket Ring 51 Transmission Case
35 Snap (Turbine Shaft-to-Drive Sprocket) Ring 52 Vent Cap
36 Drive Link Assembly 53 Drive Sprocket Support Screw
37 Drive Sprocket 54 Converter Seal
38 Thrust (Drive Sprocket-to-Support) Washer 56 Output/Stub Shaft Sleeve
39 Turbine Shaft 57A Output/Stub Shaft Snap Ring
40 Turbine Shaft-to-Support Seal 57B Output/Stub Shaft Snap Ring
41 O-ring Seal (Torque Converter) 57C Output/Stub Shaft Snap Ring
42 Drive Sprocket Support Bearing 58 Output Stub Shaft
43 Drive Sprocket Support 60 Case-to-Final Drive Bushing
44 Drive Sprocket Support Bushing 91 Driven Sprocket
45 Dowel Pin (Channel Plate-to-Case) 92 Thrust (Driven Sprocket-to-Support) Washer

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 35

94 Output Shaft 107 Thrust Bearing

95 Driven Sprocket Support Assembly 108 Input Flange & Forward Clutch Hub Assembly
96 2nd Clutch Waved Plate 109 Thrust Washer
97 2nd Clutch Steel Plate 110 Forward Clutch Assembly
98 2nd Clutch Fiber Plate 111 LO/Reverse Band
99 2nd Clutch Backing Plate 112 Snap Ring (Forward Clutch Support-to-Case)
100 Intermediate/4th Band 113 Thrust Bearing
101 Thrust (Support-to-Reverse Input Clutch) 114 Forward Clutch Support Assembly
Washer 115 Sun Gear (Final Drive)
102 Reverse Input Clutch Assembly 116 Differential and Final Drive Assembly
103 Thrust Bearing 117 Thrust Bearing
104 Thrust (Selective) Washer 118 Final Drive Internal Gear
105 Direct & Coast Clutch Assembly 119 Fretting Internal Gear-to-Case Ring
106 Input Carrier Assembly

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5A -- 36 4T40-E AUTOMATIC TRANSAXLE

VALVE BODY-TO-SPACER PLATE GASKET

A103A018

1 Suction 21 1-2 Accumulator Feed

2 Line 22 3-4 Accumulator Feed
3 Decrease 23 2-3 Accumulator
4 Converter Feed 24 2-3 Accumulator Feed
5 TCC Feed Limit 25 Reverse
6 Release 27 LO Band
7 Apply 28 Drive
8 Cooler 30 2-3 Drive
10 Lube 2 31 Filtered 2-3 Drive
11 PRN 32 2nd Clutch
13 PRND4 33 TCC Signal (PWM)
14 Actuator Feed 34 TCC-Regulated Apply
17 2-3 Signal 35 3-4 Drive
18 Torque Signal 36 Direct Clutch Feed
20 1-2/3-4 Accumulator 38 4th Band

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 37

39 D321 44 LO
40 Coast Clutch 45 Exhaust
41 D21 46 Orificed Exhaust
42 Intermediate Band Feed 47 Void
43 Intermediate Band

CHANNEL PLATE PASSAGES - CASE SIDE

A103A019

1 Suction 27 LO Band
2 Line 28 Drive
3 Decrease 32 2nd Clutch
8 Cooler 36 Direct Clutch Feed
9 Lube 1 37 Direct Clutch
10 Lube 2 38 4th Band
21 1-2 Accumulator Feed 40 Coast Clutch
22 3-4 Accumulator Feed 43 Intermediate Band
24 2-3 Accumulator Feed 45 Exhaust
25 Reverse 47 Void

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5A -- 38 4T40-E AUTOMATIC TRANSAXLE

CASE PASSAGES - CHANNEL PLATE SIDE

A103A020

1 Suction 28 Drive
2 Line 32 2nd Clutch
8 Cooler 37 Direct Clutch
9 Lube 1 38 4th Band
10 Lube 2 40 Coast Clutch
24 Direct Clutch Feed 43 Intermediate Band
25 Reverse 45 Exhaust
27 LO Band 47 Void

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 39

CASE PASSAGES - BOTTOM

A103A021

1 Suction 38 4th Band

10 Lube 2 43 Intermediate Band
25 Reverse 45 Exhaust
27 LO Band 47 Void
28 Drive

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5A -- 40 4T40-E AUTOMATIC TRANSAXLE

SPACER PLATE-TO-CHANNEL PLATE GASKET

A103A022

1 Suction 20 1-2/3-4 Accumulator

2 Line 21 1-2 Accumulator Feed
3 Decrease 22 3-4 Accumulator Feed
4 Converter Feed 23 2-3 Accumulator
5 TCC Feed Limit 24 2-3 Accumulator Feed
6 Release 25 Reverse
7 Apply 27 LO Band
8 Cooler 28 Drive
10 Lube 2 30 2-3 Drive
11 PRN 32 2nd Clutch
12 LO/PRN 33 TCC Signal (PWM)
13 PRND4 34 TCC-Regulated Apply
14 Actuator Feed 35 3-4 Drive
17 2-3 Signal 36 Direct Clutch Feed
18 Torque Signal 37 Direct Clutch

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 41

38 4th Band 43 Intermediate Band

39 D321 44 LO
40 Coast Clutch 45 Exhaust
41 D21 46 Orificed Exhaust
42 Intermediate Band Free

CHANNEL PLATE-TO-CASE GASKET

A103A023

1 Suction 27 LO Band
2 Line 28 Drive
8 Cooler 32 2nd Clutch
9 Lube 1 38 4th Band
10 Lube 2 43 Intermediate Band
24 2-3 Accumulator Feed 45 Exhaust
25 Reverse 47 Void

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5A -- 42 4T40-E AUTOMATIC TRANSAXLE

SPACER PLATE

A103A024

1 Suction 20 1-2/3-4 Accumulator

2 Line 21 1-2 Accumulator Feed
3 Decrease 22 3-4 Accumulator Feed
4 Converter Feed 23 2-3 Accumulator
5 TCC Feed Limit 24 2-3 Accumulator Feed
6 Release 25 Reverse
7 Apply 27 LO Band
8 Cooler 28 Drive
10 Lube 2 30 2-3 Drive
11 PRN 31 Filtered 2-3 Drive
12 LO/PRN 32 2nd Clutch
13 PRND4 33 TCC Signal (PWM)
14 Actuator Feed 34 TCC-Regulated Apply
17 2-3 Signal 35 3-4 Drive
18 Torque Signal 36 Direct Clutch Feed

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 43

37 Direct Clutch 43 Intermediate Band

38 4th Band 44 LO
39 D321 45 Exhaust
40 Coast Clutch 46 Orificed Exhaust
42 Intermediate Band Feed

PUMP BODY OIL CHANNELS

A103A025

1 Suction 3 Decrease
2 Line 47 Void

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5A -- 44 4T40-E AUTOMATIC TRANSAXLE

4T40-E LEAK INSPECTION POINTS

A103A026

1 Actuator Guide Seal 9 Torque Converter

2 Case 10 Fluid Level Plug
3 Cooler Line Seals 11 Output Speed Sensor Seal
4 Line Pressure Plug 12 Fill Cap Seal and Vent
5 Axle Seal (Case) and Stub Shaft Sleeve 13 Axle Seal (Side Cover) and Output Shaft
6 Manual Shaft Seal Sleeve
7 Pass-Thru Connector Seal 14 Side Cover Seals
8 Converter Seal 15 Bottom Pan Gasket

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 45

ELECTRONIC COMPONENT LOCATION VIEWS

A103A027

13 Pressure Switch Assembly 46 Input Speed Sensor

305 1-2/2-3 Shift Solenoid 312 Pressure Control Solenoid
62 Output Speed Sensor 335 TCC Control PWM Solenoid

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5A -- 46 4T40-E AUTOMATIC TRANSAXLE

CONTROL VALVE BODY CHANNELS - CHANNEL PLATE SIDE

A103A028

1 Suction 18 Torque Signal

2 Line 19 PCS Signal
3 Decrease 20 1-2/3-4 Accumulator
4 Converter Feed 21 1-2 Accumulator Feed
5 TCC Feed Limit 22 3-4 Accumulator
6 Release 23 2-3 Accumulator
7 Apply 24 2-3 Accumulator Feed
8 Cooler 25 Reverse
10 Lube 2 27 LO Band
11 PRN 28 Drive
12 LO/PRN 30 2-3 Drive
13 PRND4 32 2nd Clutch
14 Actuator Feed 33 TCC Signal (PCM)
15 Filtered Actuator Feed 34 TCC-Regulated Apply
16 1-2 Signal 35 3-4 Drive
17 2-3 Signal 37 Direct Clutch

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 47

38 4th Band 43 Intermediate Band

39 D321 44 LO
40 Coast Clutch 45 Exhaust
41 D21 46 Orificed Exhaust
42 Intermediate Band Feed 47 Void

CONTROL VALVE BODY CHANNELS - OIL PUMP SIDE

A103A029

1 Suction 28 Drive
2 Line 41 D21
6 Release 44 LO
13 PRND4 45 Exhaust
25 Reverse 47 Void

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5A -- 48 4T40-E AUTOMATIC TRANSAXLE

CHANNEL PLATE PASSAGES - CONTROL VALVE BODY SIDE

A103A030

1 Suction 20 1-2/3-4 Accumulator

2 Line 21 1-2 Accumulator Feed
3 Decrease 22 3-4 Accumulator
4 Converter Feed 23 2-3 Accumulator
5 TCC Feed Limit 24 2-3 Accumulator Feed
6 Release 25 Reverse
7 Apply 27 LO Band
8 Cooler 28 Drive
9 Lube 1 30 2-3 Drive
10 Lube 2 32 2nd Clutch
11 PRN 33 TCC Signal (PWM)
12 LO/PRN 34 TCC-Regulated Apply
13 PRND4 35 3-4 Drive
14 Actuator Feed 36 Direct Clutch Feed
17 2-3 Signal 37 Direct Clutch
18 Torque Signal

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 49

DIAGNOSIS
BASIC KNOWLEDGE REQUIRED gauge set. The functional test procedure is designed to
verify the correct operation of electronic components
You must be familiar with some basic electronics to use
in the transaxle. This will eliminate the unnecessary re-
this section of the Service Manual. They will help you to
moval of transaxle components.
follow diagnostic procedures.
Notice: Lack of basic knowledge of this powertrain
when performing diagnostic procedures could result in
FUNCTIONAL CHECK PROCEDURE
incorrect diagnostic performance or damage to power- Begin with the Functional Check Procedure which pro-
train components. Do not, under any circumstances, at- vides a general outline of how to diagnose HYDRA-
tempt to diagnose a transmission problem without this MATIC 4T40-E. The Functional Check Procedure will
basic knowledge. indicate the proper path of diagnosing the transaxle by
describing the basic checks and then referencing the
Notice: If a wire is probed with a sharp instrument and locations of the specific checks.
not properly sealed afterward, the wire will corrode and
an open circuit will result. Use on-board diagnostics or TECH 1 (or other scan tool)
to see if any transaxle trouble codes have been set. Re-
Diagnostic test probes are now available that allow you fer to the appropriate “Diagnostic Trouble Code” infor-
to probe individual wires without leaving the wire open to mation and repair the vehicle as directed. After repairing
the environment. These probe devices are inexpensive the vehicle, perform the road test and verify that the
and easy to install, and they permanently seal the wire code has not set again.
from corrosion.
If no trouble codes have been set and the condition is
Special Tools suspected to be hydraulic, take the vehicle on a road
You should be able to use a Digital Volt Meter (DVM), a test. Refer to “Road Test Procedure” in this section.
circuit tester, jumper wires or leads and a line pressure

4T40-E TRANSAXLE FUNCTIONAL CHECK PROCEDURE

Step Action Value(s) Yes No
Perform the Fluid Level Service Procedure.
1 - -
Is the fluid level correct? Go to Step 2
Check for PCM trouble codes, both current and Go to Tech 1
2 history. - Data Value
Are PCM trouble codes present? Examples Go to Step 3
1. Perform the Electrical/Garage Shift Tests.
3 2. Perform the Road Test Procedure. -
Was the condition duplicated? Go to Step 4 Go to Step 12
4 Is a harsh or soft shift condition present? - Go to Step 7 Go to Step 5
Is the vehicle’s performance poor? Go to Torque
Converter
Evaluation
- section of
5
‘‘Torque
Converter
Clutch
Diagnosis’’ Go to Step 6
Is the engagement into Drive or Reverse delayed or
6
missing? - Go to Step 7 Go to Step 9
Perform the Line Pressure Check Procedure. Refer to
Is the line pressure correct? - Symptom
7
Diagnosis
Go to Step 8 Charts

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5A -- 50 4T40-E AUTOMATIC TRANSAXLE

4T40-E Transaxle Functional Check Procedure (Cont’d)

Step Action Value(s) Yes No
Inspect the transmission wire harness connectors Refer to
and the transmission range switch. - Symptom
8
Was the problem found and corrected? Diagnosis
System OK Charts
Is vibration or noise a problem? Refer to
Vibration Test
Procedure of
9 - ‘‘Torque
Converter
Clutch
Diagnosis’’ Go to Step 10
Is the fluid leaking? Refer to
10 - Leak Diagnosis
and Repair Go to Step 11
Are other transmission conditions present? Refer to
11 - Symptom
Diagnosis Chart Go to Step 12
The condition is intermittent.
12 - -
Re-examine the complaint. Exit Table

LINE PRESSURE CHECK 4. Repair vehicle if necessary.

PROCEDURE Inspect
The HYDRA-MATIC 4T40-E uses a vane type oil pump D Fluid level
to produce hydraulic pressure, and a transaxle pressure D Manual linkage
control solenoid to control that pressure at the pressure Install or Connect
regulator valve, after it leaves the pump. The transaxle
D TECH 1 (Scan tool)
pressure control solenoid is controlled by an electrical
signal that ranges from 0 to 1.1 amp 1.1 amp corre- D Oil pressure gage at line pressure tap
sponds to minimum line pressure (approx. 310 to 380
kPa: 45-55 psi not 0 psi) and 0 amps corresponds to a
maximum line pressure (approx. 965 to 1240 kPa: 140
to 180 psi) in Overdrive (D).
Line pressures are calibrated for two sets of gear ranges
- Drive-Park-Neutral and Reverse. This allows the
transaxle line pressure to be appropriate for different
pressure needs in different gear ranges:

Gear Range Nominal Line Pressure Range

Drive, Park or Neutral 50-160 psi (345-1103 kPa)
Reverse 58-186 psi (400-1282 kPa)

Before performing a line pressure check, verify that the

pressure control solenoid is receiving the correct electri-
cal signal from the TCM:
1. Install a scan tool.
A103A031
2. Start the engine and set parking brake.
3. Check for a stored pressure control solenoid diagnos-
tic trouble code, and other diagnostic trouble codes. 5. Put gear selector in Park and set the parking brake.
6. Start engine and allow it to warm up at idle.

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 51
7. Access the “PCS Control” test on the TECH 1 (scan Caution: Brakes must be applied at all times to
tool). prevent unexpected vehicle motion.
8. Increase DESIRED PCS in 0.1 Amp increments and If pressure readings differ greatly from the line pressure
read the corresponding line pressure on the pressure chart, refer to the Diagnosis Charts contained in this
gage. (Allow pressure to stabilize for 5 seconds after section.
each current change.)
The TECH 1 scan tool is only able to control the pres-
9. Compare data to the Drive-Park-Neutral line pressure sure control solenoid in Park and Neutral with the ve-
chart below. hicle stopped. This protects the clutches from extremely
Notice: Total test running time should not exceed 2 high or low pressures in Drive or Reverse ranges.
minutes, or transaxle damage could occur.

Pressure Control Solenoid Current Approximate Line Pressure

(Amp) (psi)
0.00 152-160
0.10 149-151
0.30 141-143
0.50 124-127
0.60 111-115
0.70 97-101
0.80 81-84
0.90 64-67
0.95 56-58
1.00 50-51
1.05 50
1.10 50
NOTE: Pressures are at 705C and vary with temperature. Pressure drops as temperature increases.

COMPONENT RESISTANCE CHECK PROCEDURE

Pass Through Resistance Resistance Resistance to
Component
Pins 20_C (68_F) 100_C (212_F) Ground (Case)
Greater than
1-2 Shift Solenoid Valve A, E 19-24W 24-31W
250KW
Greater than
2-3 Shift Solenoid Valve B, E 19-24W 24-31W
250KW
Torque Converter Clutch Pulse Width Greater than
T, E 10-11W 13-15W
Modulation Solenoid Valve 250KW
Greater than
Pressure Control Solenoid Valve C, D 3-5W 4-7W
250KW
Transmission Fluid Pressure Switch Refer to Pressure Switch Assembly Resistance Check
*Transmission Fluid Temperature (TFT) Greater than
L, M 3106-3923W 164-190W
Sensor 20MW
Automatic Transmission Input (Shaft) Greater than
S, V 615-700W 750-835W
Speed Sensor 10MW
Automatic Transmission Output Greater than
A, B 1530-1650W 1700-1870W
Speed Sensor 10MW
Important: The resistance of this device is necessarily dependent on the temperature. Therefore the resistance
will vary far more than any other device.

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5A -- 52 4T40-E AUTOMATIC TRANSAXLE

PRESSURE SWITCH ASSEMBLY RESISTANCE CHECK

Step Action Value(s) Yes No
1. Install J 39775 Jumper Harness on the
transmission 20-way connector, if needed.
2. Using J 39200 DVOM and J 35616 Connector
1
Test Adapter Kit, measure the resistance from
terminal U and the transmission case.
Is the resistance less than the value shown? 50W Go to Step 3 Go to Step 2
1. Disconnect the internal transmission harness
from the TFP Val. Position Sw.
2 2. Measure the resistance from terminal D and the
TFP Val. Position Sw. housing.
Is the resistance less than the value shown? 50W Go to Step 15 Go to Step 17
Measure the resistance from terminal N and the
3 transmission case.
Is the resistance more than the value shown? 50KW Go to Step 5 Go to Step 4
1. Disconnect the internal transmission harness
from the TFP Val. Position Sw.
4 2. Measure the resistance from terminal A and the
TFP Val. Position Sw. housing.
Is the resistance more than the value shown? 50KW Go to Step 15 Go to Step 17
Measure the resistance from terminal R and the
5 transmission case.
Is the resistance more than the value shown? 50KW Go to Step 7 Go to Step 6
1. Disconnect the internal transmission harness
from the TFP Val. Position Sw.
6 2. Measure the resistance from terminal B and the
TFP Val. Position Sw. housing.
Is the resistance more than the value shown? 50KW Go to Step 15 Go to Step 17
Measure the resistance from terminal P and the
7 transmission case.
Is the resistance more than the value shown? 50KW Go to Step 9 Go to Step 8
1. Disconnect the internal transmission harness
from the TFP Val. Position Sw.
8 2. Measure the resistance from terminal C and the
TFP Val. Position Sw. housing.
Is the resistance more than the value shown? 50KW Go to Step 15 Go to Step 17
1. Start the engine and let the engine idle.
2. Set the parking brake.
3. Place the gear selector in P (Park).
9
4. Measure the resistance from terminal U and the
transmission case.
Is the resistance more than the value shown? 50KW Go to Step 10 Go to Step 17
1. Place the gear selector in R (Reverse).
2. Measure the resistance from terminal P and the
10
transmission case.
Is the resistance less than the value shown? 50W Go to Step 11 Go to Step 17
1. Place the gear selector in D4 (Drive).
2. Measure the resistance from terminal N and the
11
transmission case.
Is the resistance less than the value shown? 50W Go to Step 12 Go to Step 17

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 53

Pressure Switch Assembly Resistance Check (Cont’d)

Step Action Value(s) Yes No
Measure the resistance from terminal R and the
12 transmission case.
Is the resistance less than the value shown? 50W Go to Step 13 Go to Step 17
1. Place the gear selector in D1 (Low).
2. Measure the resistance from terminal N and the
13
transmission case.
Is the resistance less than the value shown? 50W Go to Step 14 Go to Step 17
Measure the resistance from terminal P and the
14 transmission case. No problem
Is the resistance less than the value shown? 50W found; exit table Go to Step 17
Inspect for high resistance:
D Inspect the transmission wiring for poor electrical
connections at the transmission 20-way
connector and at the TFP Val. Position Sw.
15 connector. -
D Look for possible bent, backed out, deformed, or
damaged terminals.
D Check for weak terminal tension. Verify repair and
Was the condition found? Go to Step 1 Go to Step 16
Replace the internal wiring harness. Verify repair and
16 - -
Is the replacement complete? Go to Step 1
Replace the TFP Val. Position Sw. Verify repair and
17 - -
Is the replacement complete? Go to Step 1

CLUTCH PLATE DIAGNOSIS Causes of Burned Clutch Plates

Composition Plates The following conditions can result in a burned clutch
plate:
Dry the plates and inspect the plates for the following
conditions: D Incorrect usage of clutch plates.
D Pitting D Engine coolant in the transmission fluid.
D Flaking D A cracked clutch piston.
D Wear D Damaged or missing seals.
D Glazing D Low line pressure.
D Cracking D Valve problems.
D Charring - The valve body face is not flat
- Porosity between channels
D Chips or metal particles embedded in the lining - The valve bushing clips are improperly installed
Replace a composition plate which shows any of these - The check balls are misplaced
conditions. D The Teflonr seal rings are worn or damaged.
Steel Plates
Wipe the plates dry and check the plates for heat dis- ENGINE COOLANT IN TRANSAXLE
coloration. If the surfaces are smooth, even if color Notice: Antifreeze will deteriorate the Viton O-ring seals
smear is indicated, you can reuse the plate. If the plate and the glue used to bond the clutch material to the
is discolored with heat spots or if the surface is scuffed, pressure plate. Both conditions may cause transaxle
replace the plate. damage.
Important: If the clutch shows evidence or extreme Perform the following steps if the transmission oil cooler
heat or burning, replace the springs. has developed a leak, allowing engine coolant to enter
the transmission:

DAEWOO J-100 BL2 / BL3

5A -- 54 4T40-E AUTOMATIC TRANSAXLE
1. Because the coolant will attach the seal material 3. Operate the vehicle for about 25 km (15 miles) or until
causing leakage, disassemble the transmission and the transmission reaches normal operating tempera-
replace all rubber type seals. ture (88_C, 190_F).
2. Because the facing material may become separated 4. Park the vehicle over clean paper or cardboard.
from the steel center portion, replace the composition- 5. Shut the engine off and look for fluid spots on the pa-
facedclutch plate assemblies. per.
3. Replace all nylon parts including washers. 6. Make the necessary repairs to correct the leak.
4. Replace the torque converter.
Powder Method
5. Thoroughly clean and rebuild the transmission, using
1. Thoroughly clean the suspected leak area.
new gaskets andoil filter.
2. Apply an aerosol type powder (foot powder) to the
6. Flush the cooler lines after you have properly repaired
suspected leak area.
or replacedthe transmission cooler.
3. Operate the vehicle for about 25 km (15 miles) or until
the transmission reaches normal operating tempera-
COOLER FLUSHING AND FLOW ture (88_C, 190_F).
TEST 4. Shut the engine off.
Notice: You must flush the cooler whenever you remove 5. Inspect the suspected leak area and trace the leak
a transmission for service. Cooler flushing is essential path through the powder to find the source of the
for SRTA installation, major overhaul, whenever you re- leak.
place a pump or torque converter, or whenever you sus- 6. Make the necessary repairs.
pect that the fluid has been contaminated. Use J 35944
to flush the cooler. Dye and Black Light Method
After filling the transmission with fluid, start the engine 1. Add dye to the transaxle though the transmission fill
and run for 30 seconds. This will remove any residual cap. Follow the manufacturer’s recommendation for
moisture from the oil cooler. A minimum of two quarts the amount of dye to be used.
of fluid should flow during a 30-second period. To check 2. Use the black light to find the fluid leak.
the fluid flow, disconnect the return line at the transmis- 3. Make the necessary repairs.
sion and observe the flow with the engine running. If the
fluid flow is insufficient, check the fluid flow by discon-
Repairing the Fluid Leak
necting the feed line at the cooler. Observe the flow with Once the leak point is found the source of the leak must
the engine running. be determined. Figure 10 shows potential leak points for
the transaxle. The following list describes the potential
D If the flow from the cooler return line at the transmis- causes for the leak:
sion is insufficient, check the flow rate from the feed
D Fasteners are not torqued to specification.
line to the cooler. Blockage exists in the transmission
or the cooler. D Fastener threads and fastener holes are dirty or
corroded.
D If the flow from the transmission feed line to the cool-
er is insufficient, the transmission is the cause of the D Gaskets, seals or sleeves are misaligned, damaged
fluid flow problem. or worn.
D If the flow from the transmission feed line to the cool- D Damaged, warped or scratched seal bore or gasket
er is insufficient, but flow from the cooler return line to surface.
the transmission is insufficient, inspect the cooler D Manual shaft nicked or damaged.
pipes and fittings. Then repeat the cooler flushing D Loose or worn bearing causing excess seal or sleeve
procedure. If the flow is still insufficient, replace the wear.
cooler.
D Case or component porosity.
D Fluid level too high.
FLUID LEAK DIAGNOSIS AND
D Plugged vent or damaged vent tube.
REPAIR
D Water or coolant in fluid.
The cause of most external leaks can generally be lo-
cated and repaired with the transmission in the vehicle. D Fluid drain back holes plugged.

Methods for Locating Leaks CASE POROSITY REPAIR

General Method Some external leaks are caused by case porosity in
1. Verify that the leak is transmission fluid. non-pressurized areas. You can usually repair these
2. Thoroughly clean the suspected leak area. leaks with the transmission in the car.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 55
1. Thoroughly clean the area to be repaired with a level was in the correct operating range. Allow the
cleaning solvent. Air dry the area. fluid to finish draining through the screw hole and
2. Using instructions from the manufacturer, mix a install the fluid level screw. Torque the fluid level
sufficient amount of epoxy, GM P/N 1052533 or screw to the proper specification (12 Nwm).
equivalent, to make the repair. D If fluid does not drain through the screw hole after
Caution: Epoxy adhesive may cause skin irritations adding a total of 1.5 liters then the transaxle was
and eye damage. Read and follow all information on either underfilled or is leaking fluid. The transaxle
the container label as provided by the manufacturer. should be inspected for fluid leaks and any leaks
should be fixed before setting the transaxle fluid
3. While the transmission case is still hot, apply the level.
epoxy. You can use a clean, dry soldering acid brush
6. When the fluid level checking procedure is com-
to clean the area and also to apply the epoxy cement. pleted, wipe any fluid from the transaxle case with a
Make certain that the area to be repaired is fully rag or shop towel. Also, check that the fluid fill cap
covered.
and vent tube are properly installed.
4. Allow the epoxy cement to cure for three hours before
starting the engine. Fluid Level Set After Service
5. Repeat the fluid leak diagnosis procedures. 1. Depending on the service procedure performed, add
the following amounts of fluid through the fill cap hole
prior to adjusting the fluid level:
4T40-E FLUID LEVEL SERVICE
Bottom pan removal 7 liters (7.4 quarts)
PROCEDURE (on-vehicle)
The fluid level screw is intended to be used for diagnos-
New converter 2.5 liters (2.6 quarts)
ing a transaxle fluid leak or resetting the transaxle fluid
level after service that involves a loss of fluid. Complete overhaul 10 liters (10.6 quarts)
2. Follow steps 1 thru 4 of the Fluid Level Diagnosis
Fluid Level Diagnosis Procedure Procedure.
The fluid level should be checked when the transmission
3. Add additional fluid through the fill cap hole in 0.5 liter
is above 40_C (104_F). This temperature can be reached
(1 pint) increments until fluid comes out the screw
by performing the following procedure.
hole.
1. Park the vehicle on a hoist, inspection pit or similar
raised level surface. The vehicle must be level to ob-
tain a correct fluid level measurement.
2. Place a fluid container below the fluid level screw.
3. Start the engine and allow the engine to idle for
approximately 5 minutes or, if possible, drive the vehi-
cle for a few kilometers to warm the transaxle fluid.
4. With the brake pedal depressed, move the shift lever
through the gear ranges, pausing a few seconds in
each range. Return the shift lever to the P (Park)
position.
5. Remove the fluid level screw. Because the transaxle
operates correctly over a range of fluid levels, fluid
may or may not drain out of the screw hole when the
screw is removed.
Caution: Removal of the fluid level screw when the
transmission fluid is hot may cause injury if fluid
drains from the screw hole. A103A032

D If fluid drains through the screw hole the transaxle

may have been overfilled. When the fluid stops
draining the fluid level is correct. Install the fluid 4. Allow the fluid to finish draining out the screw hole,
level screw and torque to the proper specification install the fluid level screw and torque the screw to the
(12 NSm). proper specifications (12 NSm).
D If fluid does not drain through the screw hole the 5. When the fluid level setting procedure is completed,
transaxle fluid level may be low. Add fluid through wipe any fluid from the transaxle case with a rag or
the fill cap hole in 0.5 liter increments, up to 1.5 li- shop towel. Also, check that the fluid fill cap and vent
ters maximum, until fluid drains through the screw tube are properly installed.
hole. If fluid drains through the screw hole the fluid
DAEWOO J-100 BL2 / BL3
5A -- 56 4T40-E AUTOMATIC TRANSAXLE

ELECTRICAL/GARAGE SHIFT TEST D This test should be performed when traffic and road
conditions permit.
This preliminary test should be performed before a hoist
or road test to make sure electronic control inputs are D Observe all traffic regulations.
connected and operating. If the inputs are not checked The TCM calculates upshift points based primarily on
before operating the transaxle, a simple electrical two inputs: THROTTLE ANGLE and VEHICLE SPEED.
condition could be misdiagnosed as a major transaxle When the TCM says a shift should occur, an electrical
condition. signal is sent to the shift solenoids which in turn moves
A scan tool provides valuable information and must the valves to perform the upshift.
be used on the HYDRA-MATIC 4T40-E transaxle for ac- The shift speed charts reference THROTTLE ANGLE
curate diagnosis. instead of “min throttle” or “wot” to make shift speed
1. Move gear selector to P (Park) and set the parking measurement more uniform and accurate. A scan tool
brake. should be used to monitor THROTTLE ANGLE. Some
scan tools have been programmed to record shift point
2. Connect scan tool to DLC terminal.
information. Check the instruction manual to see if this
3. Start engine. test is available.
4. Connect power to scan tool.
Upshift Procedure
5. Verify that the appropriate signals are present. These
With gear selector in Overdrive (D):
signals may include:
1. Look at the shift speed chart contained in this section
D ENGINE SPEED
and choose a percent throttle angle of 10 or 25%.
D TRANS INPUT SPEED
2. Set up the scan tool to monitor THROTTLE ANGLE
D TRANS OUTPUT SPEED and VEHICLE SPEED.
D VEHICLE SPEED 3. Accelerate to the chosen throttle angle and hold the
D TFP RANGE A/B/C throttle steady.
D PRNDL SELECT 4. As the transaxle upshifts, note the shift speed and
D DESIRED PCS commanded gear changes for:
D ACTUAL PCS D Second gear.
D PCS DUTY CYCLE D Third gear.
D BRAKE SWITCH D Fourth gear.
D ENG COOLANT TEMP
D TRANS FLUID TEMP Important: Shift speeds may vary due to slight hydrau-
lic delays responding to electronic controls. A change
D THROTTLE ANGLE
from the original equipment tire size also affects shift
D SYSTEM VOLTS speeds.
6. Monitor the BRAKE SWITCH signal while tapping the
Note when TCC applies. This should occur in fourth
brake pedal with your foot.
gear. If the apply is not noticed by an rpm drop, refer
D The BRAKE SWITCH should be on when the ped- to the “Torque Converter Clutch Diagnosis” information
al is depressed, and come off when the brake ped- contained in this section.
al is released.
The TCC should not apply unless the transaxle has
7. Monitor the PRNDL SELECT signal and move the reached a minimum operating temperature of 8_C
gear selector through all the ranges. (46_F) TRAN TEMP AND engine coolant temp of 50_C
D Verify that the PRNDL SELECT value matches the (122_F).
gear range indicated on the instrument panel or 5. Repeat steps 1-4 using several different throttle
console. angles.
D Gear selections should be immediate and not
harsh.
Part Throttle Detent Downshift
At vehicle speeds of 64 to 88 km/h (40 to 55 mph) in
8. Move gear selector to neutral and monitor the
Fourth gear, quickly increase throttle angle to greater
THROTTLE ANGLE signal while increasing and de-
than 50%.
creasing engine RPM with the accelerator pedal.
Verify that:
D THROTTLE ANGLE should increase with engine
RPM. D TCC releases.
D Transaxle downshifts to 3rd gear.
ROAD TEST PROCEDURE D 1-2 Shift Solenoid turns off.
D Perform the road test using a scan tool. D 2-3 Shift Solenoid remains on.

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 57

Full Throttle Detent Downshift Perform the following tests by accelerating at 10 percent
At vehicle speeds of 64 to 88 km/h (40 to 55 mph) TP Sensor position.
in Fourth gear, quickly increase throttle angle to its Manual Third (3)
maximum position (100%). D With vehicle stopped, move the gear selector to
Verify that: Manual Third (3) and accelerate to observe:
D TCC releases. - 1-2 shift.
D Transaxle downshifts to second gear immediately. - 2-3 shift.
D Both Shift Solenoids are off. Manual Second (2)
Manual Downshifts D With vehicle stopped, move gear selector to Manual
The shift solenoids do not control the initial 4-3 manual Second (2) and accelerate to observe:
downshift. The 4-3 manual downshift is hydraulic while - 1-2 shift.
the 3-2 and 2-1 are electronic. The solenoid states will D Accelerate to 40 km/h (35 mph) and observe:
change during, or shortly after a manual 4-3 downshift is
selected. - 2-3 shift does not occur.
- TCC does not apply.
1. At vehicle speeds of 64 to 88 km/h (40 to 55 mph)
in Fourth gear, release the accelerator pedal while Manual First (1)
moving the gear selector to Manual Third (3). Observe D With vehicle stopped, move gear selector to Manual
that: First (1). Accelerate to 32 km/h (20 mph) and observe:
D TCC releases. - No upshifts occur.
D Transaxle downshifts to third gear immediately. - TCC does not apply.
D Engine slows vehicle down. Reverse (R)
2. Move gear selector back to Overdrive (D) and accel- D With vehicle stopped, move gear selector to R (Re-
erate to 64 to 72 km/h (40 to 45 mph). Release the verse) and observe:
accelerator while moving the gear selector to Manual
Second (2) and observe that: - 1-2 Shift Solenoid is ON.
- 2-3 Shift Solenoid is OFF.
D TCC releases.
Use a scan tool to see if any transaxle trouble codes
D Transaxle downshifts to second gear immediately.
have been set. Refer to “Diagnostic Trouble Codes” in
D Engine slows vehicle down. this section and repair the vehicle as directed. After re-
3. Move gear selector back to Overdrive (D) and accel- pairing the vehicle, perform the hoist test and verify that
erate to 64 km/h (40 mph). Release the accelerator the code has not set again.
pedal while moving the gear selector to Manual First If the transaxle is not performing well and no trouble
(1) and observe that: codes have been set, there may be an intermittent
D TCC releases. condition. Check all electrical connections for damage
D Transaxle downshifts to second gear immediately. or a loose fit. Some scan tools have a snapshot test
D Engine slows vehicle down. which can help catch an intermittent condition that does
not occur long enough to set a code.
D Below 60 km/h (37 mph) transaxle downshifts to
first gear. You may want to read “Electronic Component Diagno-
sis” in this section to become familiar with transaxle
Notice: A Manual First-Third Gear Ratio will occur at conditions caused by transaxle electrical malfunctions.
high speeds as an upshift safety feature. Do not attempt
If no trouble codes have been set and the condition is
to perform this shift.
suspectedto be hydraulic, take the vehicle on a roadtest.
Coasting Downshifts
1. With the gear selector in Overdrive (D), accelerate to TORQUE CONVERTER CLUTCH
Fourth gear with TCC applied.
(TCC) DIAGNOSIS
2. Release the accelerator pedal and lightly apply the
To properly diagnose the Torque Converter Clutch
brakes, and observe that:
(TCC) system, perform all electrical testing first and then
D TCC releases. the hydraulic testing.
D Downshifts occur at speeds shown on the shift The TCC is applied by fluid pressure which is controlled
speed chart. by a solenoid located inside the Valve Body. The sole-
Manual Gear Range Selection noid is energized by completing an electrical circuit
through a combination of switches and sensors.
Upshifts in the manual gear ranges are controlled by the
shift solenoids.

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5A -- 58 4T40-E AUTOMATIC TRANSAXLE

Functional Check Procedure Perform a stall test to make sure the noise is actually
coming from the converter:
Inspect
1. Place foot on brake.
1. Install a tachometer or scan tool.
2. Put gear selector in “Drive”.
2. Operate the vehicle until proper operating tempera-
ture is reached. 3. Depress accelerator to approximately 1200 rpm for
no more than six seconds.
3. Drive the vehicle at 80 to 88 km/h (50 to 55 mph) with
light throttle (road load). Notice: If the accelerator is depressed for more than
4. Maintaining throttle, lightly touch the brake pedal and six seconds, damage to the transaxle may occur.
check for release of the TCC and a slight increase in A torque converter noise will increase under this load.
engine speed (rpm).
Important: This noise should not be confused with
5. Release the brake, slowly accelerate and check for a pump whine noise which is usually noticeable in P (Park),
re-apply of the converter clutch and a slight decrease N (Neutral) and all other gear ranges. Pump whine will
in engine speed (rpm). vary with pressure ranges.
The torque converter should be replaced under any of
TORQUE CONVERTER EVALUATION the following conditions:
Torque Converter Stator D External leaks in the hub weld area.
The torque converter stator roller clutch can have one of D Converter hub is scored or damaged.
two different type malfunctions:
D Converter pilot is broken, damaged or fits poorly into
1. Stator assembly freewheels in both directions. crankshaft.
2. Stator assembly remains locked up at all times. D Steel particles are found after flushing the cooler and
Condition A - Poor Acceleration Low Speed cooler lines.
The car tends to have poor acceleration from a stand- D Pump is damaged or steel particles are found in the
still. At speeds above 50 to 55 km/h (30 to 35 mph), converter.
the car may act normal. If poor acceleration is noted, it D Vehicle has TCC shudder and/or no TCC apply. Re-
should first be determined that the exhaust system is not place only after all hydraulic and electrical diagnoses
blocked, and the transaxle is in 1st (First) gear when have been made. (Converter clutch material may be
starting out. glazed.)
If the engine freely accelerates to high rpm in N (Neu- D Converter has an imbalance which cannot be cor-
tral), it can be assumed that the engine and exhaust rected. (Refer to Converter Vibration Test Procedure.)
system are normal. Checking for poor performance in D Converter is contaminated with engine coolant con-
“Drive” and “Reverse” will help determine if the stator is taining antifreeze.
freewheeling at all times.
D Internal failure of stator roller clutch.
Condition B - Poor Acceleration High Speed D Excess end play.
Engine rpm and car speed limited or restricted at high D Heavy clutch debris due to overheating (blue convert-
speeds. Performance when accelerating from a stand- er).
still is normal. Engine may overheat. Visual examination
of the converter may reveal a blue color from over- D Steel particles or clutch lining material found in fluid
heating. filter or on magnet when no internal parts in unit are
worn or damaged (indicates that lining material came
If the converter has been removed, the stator roller from converter).
clutch can be checked by inserting two fingers into the
splined inner race of the roller clutch and trying to turn The torque converter should not be replaced if:
the race in both directions. The inner race should turn D The oil has an odor, is discolored, and there is no
freely clockwise, but not turn or be very difficult to turn evidence of metal or clutch facing particles.
counterclockwise. D The threads in one or more of the converter bolt holes
Noise are damaged.
Torque converter whine is usually noticed when the ve- - Correct with thread insert.
hicle is stopped and the transaxle is in “Drive” or “Re- D Transaxle failure did not display evidence of damage
verse”. The noise will increase when engine rpm is or worn internal parts, steel particles or clutch plate
increased. The noise will stop when the vehicle is lining material in unit and inside the fluid filter.
moving or when the torque converter clutch is applied
because both halves of the converter are turning at the
same speed.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 59
D Vehicle has been exposed to high mileage (only). The D Fuel injector - Filter may be plugged.
exception may be where the torque converter clutch D Vacuum leak - Engine won’t get correct amount of fuel.
damper plate lining has seen excess wear by vehicles May run rich or lean depending on where the leak is.
operated in heavy and/or constant traffic, such as
D EGR valve - Valve may let in too much unburnable
taxi, delivery or police use.
exhaust gas and cause engine to run lean.
D MAP sensor - Like vacuum leak, engine won’t get
TCC SHUDDER DIAGNOSIS correct amount of fuel for proper engine operation.
The key to diagnosing Torque Converter Clutch (TCC)
D Carbon on intake valves - Restricts proper flow or
shudder is to note when it happens and under what
air/fuel mixture into cylinders.
conditions.
D Flat cam - Valves don’t open enough to let proper
TCC Shudder should only occur during the APPLY and/
fuel/air mixture into cylinders.
or RELEASE of the converter clutch; SELDOM after the
TCC plate is fully applied. D Oxygen sensor - May command engine too rich or
too lean for too long.
While TCC Is Applying Or Releasing: D Fuel pressure - May be too low.
If the shudder occurs while TCC is applying, the problem
D Engine mounts - Vibration of mounts can be multi-
can be within the transaxle or torque converter. Some- plied by TCC engagement.
thing is not allowing the clutch to become fully engaged,
not allowing clutch to release, or is trying to release and D Axle joints - Check for vibration.
apply the clutch at the same time. This could be caused D TPS - TCC apply and release depends on TPS in
by leaking turbine shaft seals, a restricted release ori- many engines. If TPS is out of specification, TCC
fice, a distorted clutch or housing surface due to long may remain applied during initial engine crowd.
converter bolts, or defective friction material on the TCC D Cylinder balance - Bad piston rings or poorly sealing
plate. valves can cause low power in a cylinder.
Shudder Occurs After TCC Has Applied: D Fuel contamination - Causes poor engine perfor-
In this case, most of the time there is nothing wrong with mance.
the transaxle! As mentioned above, once the TCC has
been applied, it is very unlikely that it will slip. Engine FLEXPLATE/TORQUE CONVERTER
problems may go unnoticed under light throttle and load, VIBRATION TEST PROCEDURE
but become noticeable after TCC apply when going up
a hill or accelerating, due to the mechanical coupling D Start engine.
between engine and transaxle. D With engine at idle speed and transaxle in P (Park) or
N (Neutral), observe vibration.
Important: Once TCC is applied there is no torque
D Key off.
converter (fluid coupling) assistance. Engine or driveline
vibrations could be unnoticeable before TCC engage- Remove or Disconnect
ment. 1. Flexplate shield attaching bolts.
Inspect the following components to avoid misdiagnosis 2. Flexplate to torque converter attaching bolts.
of TCC Shudder and possibly disassembling a transaxle 3. Rotate torque converter 120 degrees (1/3 turn).
and/or replacing a torque converter unnecessarily:
Install or Connect
D Spark plugs - Inspect for cracks, high resistance or
broken insulator. 1. Flexplate to torque converter attaching bolts.
D Plug wires - Look in each end. If there is red dust Tighten
(ozone) or black substance (carbon) present, then D Bolts to 62 NSm (46 lb. ft.).
the wires are bad. Also look for a white discoloration
2. Flexplate shield attaching bolts.
of the wire indicating arcing during hard acceleration.
D Start engine and check for vibration. Repeat
D Distributor cap and rotor - Look for broken or un-
procedure until best possible balance is obtained.
crimped parts.
D Coil - Look for black on bottom indication arcing while
engine is misfiring.

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5A -- 60 4T40-E AUTOMATIC TRANSAXLE

HYDRA-MATIC 4T40-E SHIFT SPEED CHART

Upshift Speed Information
1-2 SHIFT () /* 3 MPH) 2-3 SHIFT () /* 4 MPH) 3-4 SHIFT () /* 5 MPH)
MODEL 10% 25% 50% 100% 10% 25% 50% 100% 10% 25% 50%
TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS
WAR 8.0 12.5 20.0 28.5 16.0 25.0 39.0 54.0 26.0 36.0 57.0

Transaxle Usage and Downshift Speed Information

TCC APPLY TCC RELEASE
ENGINE DOWNSHIFTS () /* 4 MPH)
4TH GEAR 4TH GEAR
MODEL SERIES
4-3 3-2 2-1 10% 25% 10% 25%
DISP. RPO
COAST COAST COAST TPS TPS TPS TPS
WAR DAEWOO -- -- 24 12.5 7 39 47 36 41

INTERNAL WIRING HARNESS CHECK

Step Action Value(s) Yes No
1. Install J 39775 Jumper Harness on the
transmission 20-way connector, if needed.
2. Using J 39200 DVOM and J 35616 Connector Refer to
1
Test Adapter Kit, measure the resistance between Component
terminals A and E: the 1-2 Shift Solenoid Valve. Resistance
Is the resistance within the values shown? Chart Go to Step 3 Go to Step 2
1. Disconnect the internal transmission harness
from the 1-2 Shift Solenoid Valve. Refer to
2 2. Using J 39200 DVOM, measure the resistance of Component
the 1-2 Shift Solenoid Valve. Resistance
Is the resistance within the values shown? Chart Go to Step 14 Go to Step 16
Measure the resistance between terminals B and E: Refer to
the 2-3 Shift Solenoid Valve. Component
3
Is the resistance within the values shown? Resistance
Chart Go to Step 5 Go to Step 4
1. Disconnect the internal transmission harness
from the 2-3 Shift Solenoid Valve. Refer to
4 2. Using J 39200 DVOM, measure the resistance of Component
the 2-3 Shift Solenoid Valve. Resistance
Is the resistance within the values shown? Chart Go to Step 14 Go to Step 16
Measure the resistance between terminals T and E: Refer to
the TCC Sol. Valve. Component
5
Is the resistance within the values shown? Resistance
Chart Go to Step 7 Go to Step 6
1. Disconnect the internal transmission harness
from the TCC Sol. Valve. Refer to
6 2. Using J 39200 DVOM, measure the resistance of Component
the TCC Sol. Valve. Resistance
Is the resistance within the values shown? Chart Go to Step 14 Go to Step 16
Measure the resistance between terminals C and D: Refer to
the TCC Sol. Valve. Component
7
Is the resistance within the values shown? Resistance
Chart Go to Step 9 Go to Step 8

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 61

Internal Wiring Harness Check (Cont’d)

Step Action Value(s) Yes No
1. Disconnect the internal transmission harness
from the Pressure Control Solenoid Valve. Refer to
8 2. Using J 39200 DVOM, measure the resistance of Component
the Pressure Control Solenoid Valve. Resistance
Is the resistance within the values shown? Chart Go to Step 14 Go to Step 16
Measure the resistance between terminals S and V: Refer to
the A/T ISS. Component
9
Is the resistance within the values shown? Resistance
Chart Go to Step 11 Go to Step 10
1. Disconnect the internal transmission harness
from the A/T ISS. Refer to
10 2. Using J 39200 DVOM, measure the resistance of Component
the A/T ISS. Resistance
Is the resistance within the values shown? Chart Go to Step 14 Go to Step 16
Measure the resistance between terminals M and L: Refer to
the TFT Sensor. Component
11
Is the resistance within the values shown? Resistance
Chart Go to Step 13 Go to Step 12
1. Disconnect the internal transmission harness
from the TFP Val. Position Sw.
2. Using J 39200 DVOM, measure the resistance of Refer to
12
the TFT Sensor by placing the meter leads between Component
terminals E andF of the TFP Val. Position Sw. Resistance
Is the resistance within the values shown? Chart Go to Step 14 Go to Step 16
Using J 39200 DVOM and J 35616 Connector Test
Adapter Kit, measure the resistance of the internal
transmission harness from pins A, B, C, D, E, L, M, Refer to
13 S, T, and V of the transmission 20-way connector to Component
the transmission case. Resistance No problem
Is the resistance more than shown? Chart found, exit table Go to Step 15
Inspect for resistance:
D Inspect the transmission wiring for poor electrical
connections at the transmission 20-way
connector and at the component connectors.
14 -
D Look for possible bent, backed out, deformed, or
damaged terminals.
D Check for weak terminal tension. Verify repair and
Was the condition found? Go to Step 1 Go to Step 15
Replace the internal wiring harness. Verify repair and
15 - -
Is the replacement complete? Go to Step 1
Replace the component. Verify repair and
16 - -
Is the replacement complete? Go to Step 1

DAEWOO J-100 BL2 / BL3

5A -- 62 4T40-E AUTOMATIC TRANSAXLE

WIRING DIAGRAM

A103A033

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 63

4T40-E COMPONENT RESISTANCE CHART

Pass Resistance Resistance Resistance to
Component Through 20_C (68_F) 100_C (212_F) Ground (Case)
Pins Ohms Ohms Ohms
Greater than
1-2 Shift Solenoid Valve A, E 19-24W 24-31W
250KW
Greater than
2-3 Shift Solenoid Valve B, E 19-24W 24-31W
250KW
Greater than
TCC Sol. Valve T, E 10-11W 13-15W
250KW
Greater than
PC Sol. Valve C, D 3-5W 4-7W
250KW
Automatic Transmission Fluid Refer to Automatic Transmission Fluid Pressure Manual Valve
Pressure Manual Valve Position Switch Position Switch Resistance Check
Greater than
*Transmission Fluid Temperature Sensor M, L 3106-3923W 164-190W
20MW
Greater than
A/T ISS S, V 615-700W 750-835W
10MW
A, B Greater than
A/T OSS 1530-1650W 1700-1870W
(OSS) CONN 10MW
*NOTE: The resistance of this device is necessarily dependent on the temperature. Therefore the resistance
will vary far more than any other device.

AUTOMATIC TRANSMISSION FLUID PRESSURE MANUAL VALVE

POSITION SWITCH RESISTANCE CHECK
Step Action Value(s) Yes No
1. Install J 39775 Jumper Harness on the
transmission 20-way connector, if needed.
2. Using J 39200 DVOM and J 35616 Connector
1
Test Adapter Kit, measure the resistance from
terminal U and the transmission case.
Is the resistance less than the value shown? 50W Go to Step 3 Go to Step 2
1. Disconnect the internal transmission harness
from the TFP Val. Position Sw.
2 2. Measure the resistance from terminal D and the
TFP Val. Position Sw. housing.
Is the resistance less than the value shown? 50W Go to Step 15 Go to Step 17
Measure the resistance from terminal N and the
3 transmission case.
Is the resistance more than the value shown? 50KW Go to Step 5 Go to Step 4
1. Disconnect the internal transmission harness
from the TFP Val. Position Sw.
4 2. Measure the resistance from terminal A and the
TFP Val. Position Sw. housing.
Is the resistance more than the value shown? 50KW Go to Step 15 Go to Step 17
Measure the resistance from terminal R and the
5 transmission case.
Is the resistance more than the value shown? 50KW Go to Step 7 Go to Step 6

DAEWOO J-100 BL2 / BL3

5A -- 64 4T40-E AUTOMATIC TRANSAXLE

Automatic Transmission Fluid Pressure Manual Valve Position Switch

Resistance Check (Cont’d)
Step Action Value(s) Yes No
1. Disconnect the internal transmission harness
from the TFP Val. Position Sw.
6 2. Measure the resistance from terminal B and the
TFP Val. Position Sw. housing.
Is the resistance more than the value shown? 50KW Go to Step 15 Go to Step 17
Measure the resistance from terminal P and the
7 transmission case.
Is the resistance more than the value shown? 50KW Go to Step 9 Go to Step 8
1. Disconnect the internal transmission harness
from the TFP Val. Position Sw.
8 2. Measure the resistance from terminal C and the
TFP Val. Position Sw. housing.
Is the resistance more than the value shown? 50KW Go to Step 15 Go to Step 17
1. Start the engine and let the engine idle.
2. Set the parking brake.
3. Place the gear selector in P (Park).
9
4. Measure the resistance from terminal U and the
transmission case.
Is the resistance more than the value shown? 50KW Go to Step 10 Go to Step 17
1. Place the gear selector in R (Reverse).
2. Measure the resistance from terminal P and the
10
transmission case.
Is the resistance less than the value shown? 50W Go to Step 11 Go to Step 17
1. Place the gear selector in D4 (Drive).
2. Measure the resistance from terminal N and the
11
transmission case.
Is the resistance less than the value shown? 50W Go to Step 12 Go to Step 17
Measure the resistance from terminal R and the
12 transmission case.
Is the resistance less than the value shown? 50W Go to Step 13 Go to Step 17
1. Place the gear selector in D1 (Low).
2. Measure the resistance from terminal N and the
13
transmission case.
Is the resistance less than the value shown? 50W Go to Step 14 Go to Step 17
Measure the resistance from terminal P and the
14 transmission case. No problem
Is the resistance less than the value shown? 50W found; exit table Go to Step 17
Inspect for high resistance:
D Inspect the transmission wiring for poor electrical
connections at the transmission 20-way
connector and at the TFP Val. Position Sw.
15 connector. -
D Look for possible bent, backed out, deformed, or
damaged terminals.
D Check for weak terminal tension. Verify repair and
Was the condition found? Go to Step 1 Go to Step 16
Replace the internal wiring harness. Verify repair and
16 - -
Is the replacement complete? Go to Step 1
Replace the TFP Val. Position Sw. Verify repair and
17 - -
Is the replacement complete? Go to Step 1

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 65

SYMPTOM DIAGNOSIS
HIGH OR LOW LINE PRESSURE
Condition Inspect Component For Cause
HIGH OR LOW LINE PRESSURE Oil Level D High or Low: correct as required.
(V if With Gauge)
(Verify G )
Pressure Regulator Valve (328) D Stuck.
(All Shifts Harsh or Soft)
Springs (326, 327)
Boost Valve (325)
Possible Codes:
712 Trans Fluid Temp Sensor Pressure Control Solenoid (312) D Leak, O-rings damaged.
Circuit - Low Input D Loose connector, pins damaged.
713 Trans Fluid Temp Sensor D Contaminated.
Circuit - High Input
716 Input Speed Sensor Circuit Torque Signal Regulator Valve (309) D Stuck.
- Range/Performance Transmission Wiring Harness (11) D Loose connector at vehicle
p Speed
717 Input p Sensor Circuit harness, short.
- Malfunction
M lf i Transmission Fluid Pressure D Loose connector.
722 Output Speed Sensor - Switch (13) D Damaged or missing O-ring.
Malfunction
723 Output Speed Sensor - Throttle Position Sensor D Damaged, sticking, disconnected.
Intermittent/Erratic D Intermittent open or shorted
727 Engine
g Speed
p Sensor Low circuit.
730 Undefined Gear Ratio Oil Filter (85) D Clogged, broken, loose.
742 TCC Circuit Stuck ON
748 PCS Circuit - Malfunction Oil Filter Seal (84) D Leaking.
751 1-2 Shift Solenoid Cooler Lines D Clogged or restricted.
P f
Performance FFault
lt
Cooler Line Seals (49) D Leaking.
756 2-3 Shift Solenoid
Performance Oil Pump (10) D Damaged, sticking, porosity,
1810 TFP Malfunction leaking.
1811 Max Adapt/Longshift Oil Pump Drive Shaft (19) D Damaged.
1887 TCC Release Switch
Malfunction Pressure Relief Valve (214) D Damaged sprimg, ball missing.
Transaxle Case (1) D Porosity, leaking circuits.
Valve Body (18) D Flatness of machined surfaces.
Channel Plate (27)

INACCURATE/INCONSISTENT SHIFT POINTS

Condition Inspect Component For Cause
INACCURATE / INCONSISTENT Shift Solenoids (305) D Contamination.
SHIFT POINTS D Intermittent open or shorted
circuit.
Possible Codes:
716 Input Speed Sensor Circuit
- Range/Performance
Throttle Position Sensor D Damaged, disconnect.
717 Input Speed Sensor Circuit
- Malfunction D Intermittent open or shorted
722 Output Speed Sensor - circuit.
Malfunction
723 Output Speed Sensor -
Intermittent/Erratic Output Speed Sensor (62) D Damaged, disconnected, loose.
751 1-2 Shift Solenoid Input Speed Sensors (46) D Intermitten open or shorted
Performance Fault circuit.
756 2-3 Shift Solenoid
Performance

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5A -- 66 4T40-E AUTOMATIC TRANSAXLE

HARSH SHIFTS
Condition Inspect Component For Cause
HARSH SHIFTS Line Pressure D High (See High Line Pressure).
(G
(General)
l)
Checkballs (26) D Missing, no orifice applied.
Accumulators D Springs or piston binding; no
accumulation.
D Accumulator valve stuck.
Clutch Housing Retainer and D Plugged.
Ball Assemblies

NO REVERSE, SLIPS IN REVERSE

Condition Inspect Component For Cause
NO REVERSE, SLIPS IN Reverse Clutch D No apply/slipping.
REVERSE D Piston and Seal Assembly (457) D Binding, cracked, leaking.
D Inner Seal (456) D Orifice plugged.
Possible Codes:
D Clutch Plates (460-463) D Friction worn, splines broken.
1810 TFP Malfunction with Input
Speed Sensor D Snap Ring (459, 464) D Out of position.
D Housing D Cracked, feed holes plugged,
tangs broken.
D Housing Retainer and D Missing/out of position.
Ball Assembly
D Springs (458) D Binding.
Reverse Clutch Fluid Routing D Fluid leak/restriction.
D Driven Sprocket Support (95) D Seal rings leaking.
D Porosity, damaged, misaligned.
D Channel Plate & Gasket, Valve D Porosity, fluid leak across
Body, Gaskets and Channel Plate channels, misaligned, damaged,
fluid restriction.
Lo & Reverse Band and Servo D No apply/slipping.
D Servo Piston (69) D Broken, binding.
D Servo Piston Seals (71, 72) D Leaking.
D Servo Pin (67) and D Binding.
Springs (66, 68)
D Servo Cover (73) D Broken, loose, leaking.
D Lo & Reverse Band (111) D Broken, worn, out of position.
D Anchor Pin (64) D Broken.
D Fluid Feed Tubes (83) D Broken, bent, plugged, seal rings
missing/leaking.
D Transaxle Case (1) D Porosity, fluid leak or restriction.
Shift Linkage D Disconnected, misaligned.
Manual Valve (800) D Disconnected, misaligned.
Link (802)
#1 Checkball (LO/PRN) D Missing (No LO Band Fluid).
Fluid Level D Low.
Fluid Pressure D Low (See Low Fluid Pressure).

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 67

NO FIRST GEAR, SLIPS IN FIRST GEAR

Condition Inspect Component For Cause
NO FIRST GEAR, SLIPS IN Forward Clutch D No apply/slipping.
FIRST GEAR D Piston and Seal Assembly (607) D Binding, cracked, leaking.
D Inner Seal (608) D Orifice plugged.
Possible Codes:
D Clutch Plates (601-604) D Splines, broken, friction worn.
716 Input Speed Sensor Circuit
- Range/Performance D Snap Ring (600, 605) D Out of position.
717 Input Speed Sensor Circuit D Housing (609) D Cracked, feed holes plugged.
- Malfunction D Housing Retainer and D Missing, out of position.
722 Output Speed Sensor - Ball Assembly
Malfunction D Springs (606) D Binding.
723 O Output SSpeed dS
Sensor Input Sprag (515) D Damaged, not holding.
Circuit- Intermittent/Erratic
730 Undefined Gear Ratio LO Roller Clutch (652) D Damaged, not holding.
751 1-2 Shift Solenoid Forward Clutch Fluid Routing D Fluid leak or restriction.
Performance Fault D Oil Feed Tubes (83) D Bent, broken, seal rings leaking,
756 2-3 Shift Solenoid plugged.
Performance
D Forward Clutch Support (114) D Porosity, seal rings leaking,
1810 PSA Malfunction with Input damaged, feed holes plugged.
Speed Sensor
D Channel Plate (27) and D Porosity, misaligned, fluid leak
Gasket (28) across channels or restriction.
D TFP (13) D Drive switch O-ring leaking.
1-2 Shift Solenoid (305) D Failed OFF, leaking.
1-2 Shift Valve (302) D Stuck in upshifted position.
2-3 Shift Solenoid (305) D Failed ON, exhaust plugged.
Manual Valve (800)/Shift Linkage D Misaligned.
Torque Converter (55) D Stator roller clutch not holding.
Line Pressure D Low (See Low Line Pressure).

NO SECOND GEAR, SLIPS IN SECOND GEAR

Condition Inspect Component For Cause
NO SECOND GEAR, SLIPS IN 2nd Clutch D No apply/slipping.
SECOND GEAR D Piston and Seal Assembly (404) D Binding, cracked, leaking.
D Clutch Plates (96-99) D Friction worn, splines broken.
Possible Codes:
D Snap Ring (406) D Out of position.
730 Undefined Gear Ratio
D Springs (405) D Binding.
751 1-2 Shift Solenoid
Performance D Driven Sprocket Support (95) D Damaged, leaking, porosity.
2nd Clutch Fluid Routing D Fluid leak or restriction.
Valve Body D Porosity, misaligned, loose,
Gaskets & Spacer Plate restriction, fluid leak across
Channel Plate & Gasket channels.
Driven Sprocket Support
2nd Roller Clutch (452) D Damaged, not holding.
1-2 Shift Solenoid (305) D Stuck ON, plugged.
Forward Clutch D Low capacity shows up in 2nd
gear.
Line Pressure D Low (See Low Line Pressure).

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5A -- 68 4T40-E AUTOMATIC TRANSAXLE

No Second Gear, Slips in Second Gear (Cont’d)

Condition Inspect Component For Cause
NO SECOND GEAR, SLIPS IN 1-2 Accumulator (29-31) D Leak at piston seal.
SECOND GEAR (Continued) D Channel plate/case porosity.
1-2 Accumulator Valve (323) D Stuck.
2-3 Shift Valve (306) D Stuck in upshifted position.
TFP (13) D Malfunction
(Electrical or Hydraulic)

NO THIRD GEAR, SLIPS IN THIRD GEAR

Condition Inspect Component For Cause
NO THIRD GEAR, SLIPS IN Direct Clutch D No apply/slipping.
THIRD GEAR D Piston and Seal Assembly (518) D Binding, cracked, leaking.
D Clutch Plates (521-523) D Friction worn, splines broken.
Possible Codes:
D Snap Ring (520) D Out of position.
756 2-3 Shift Solenoid
Performance D Springs (519) D Binding.
1871 Undefined Gear Ratio D Direct & Coast Housing and D Damaged, cracked, feed holes
Input Shaft (520) restricted.
D Housing Retainer and D Missing, loose.
Ball Assembly
Direct Clutch Fluid Routing
D Valve Body D Porosity, misaligned, loose, fluid
Gaskets & Spacer Plate restriction, fluid leak across
Channel Plate & Gasket channels.
Driven Sprocket Support
D Driven Sprocket Support Seals D Leaking.
D Input Shaft D Seals leaking.
D Sleeve damaged, misaligned.
2-3 Shift Solenoid (305) D Stuck OFF, leaking.
2-3 Accumulator D Leak at piston seal.
D Channel plate/case porosity.
2-3 Accumulator Valve (330) D Stuck.
Line Pressure D Low (See Low Line Pressure).
3-4 Shift Valve (319) D Stuck in upshifted position.
TFP (13) D Malfunction
(Electrical or Hydraulic).

SECOND GEAR ONLY

Condition Inspect Component For Cause
SECOND GEAR ONLY 1-2 Shift Valve (302) D Stuck in downshifted position.

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 69

NO FOURTH GEAR, SLIPS IN FOURTH GEAR

Condition Inspect Component For Cause
NO FOURTH GEAR, SLIPS IN Intermediate/4th Band & Servo D No apply/slipping.
FOURTH GEAR D Servo Piston (77) D Broken, binding.
D Servo Piston Seals (78, 79) D Leaking.
Possible Codes:
D Servo Pin (76) D Binding.
751 1-2 Shift Solenoid Springs (75, 68)
Performance Fault
D Servo Cover (80) D Broken, loose, leaking.
1871 Undefined Gear Ratio
D Band (100) D Broken, worn, out of position.
D Case (1) D Cracket at band seat.
Band Apply Fluid Routing
D Valve Body D Porosity, misaligned, loose, fluid
Gaskets & Spacer Plate restriction, fluid leak across
Channel Plate; Gasket channels.
1-2 Shift Solenoid (305) D Stuck OFF, leaking.
3-4 Shift Valve (319) D Stuck in downshifted position.
Manual Valve (800) D Misaligned (in Manual Third).
3-4 Accumulator D Leak at piston seal.
D Channel plate/case porosity.
3-4 Accumulator Valve (323) D Stuck.
Line Pressure D Low (See Low Line Pressure).
Direct Clutch D Low capacity will cause failure in
Fourth gear.
TFP (13) D Malfunction
(Electrical or Hydraulic).

LOSS OF DRIVE
Condition Inspect Component For Cause
LOSS OF DRIVE Torque Converter (55) D Broken lugs, failed lug weld.
D Sheared lug bolts.
D Worn turbine shaft splines.
D Internal failure.
D Cracked cover at weld.
Axles D Damaged, splines worn, loose.
Turbine Shaft (39) D Stripped splines.
Oil Pump (10) D Seized, broken pump gears.
Oil Pump Shaft (19) D Broken, stripped splines.
Filter and Filter Seal (85, 84) D Plugged, missing.
Fluid Level D Low.
Shift Linkage D Disconnected.
Drive/Driven Sprockets and D Broken.
Drive Chain (36, 37, 91)
Planetary Gears D Failure, lack of lube.
Final Drive D Gear failure, lack of lube.

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5A -- 70 4T40-E AUTOMATIC TRANSAXLE

Loss of Drive (Cont’d)

Condition Inspect Component For Cause
LOSS OF DRIVE ((Continued)) Channel Plate and Gasket (28) D Damaged, leaking, misaligned.
Valve Body D Damaged, leaking, misaligned.
Gaskets and Spacer Plate
Forward Sprag Clutch D Damaged, not holding.
Forward Clutch (See No First Gear)
LO Roller Clutch
Hydraulic System D Tie up, fluid circuit leaks.

LOSS OF POWER
Condition Inspect Component For Cause
LOSS OF POWER Fluid Level D Low.

Possible Codes: Shift Solenoids (305) D Failed OFF, 2nd gear start.
751 1 2 Shift Solenoid
1-2 D 2-3 Shift Solenoid, failed ON.
Performance Fault TCC System D TCC stuck ON or dragging.
756 2 2-3
3 Shift Solenoid
Performance Torque Converter (55) D Contaminated, damaged.

ENGINE STALL
Condition Inspect Component For Cause
ENGINE STALL TCC System D TCC stuck ON or dragging.
D TCC Solenoid (335) D Stuck ON, solenoid exhaust
Possible Codes: plugged.
742 TCC Circuit Stuck ON D TCC-RegulatedApply Valve (339) D Stuck in apply position.

FIRST AND SECOND GEARS ONLY

Condition Inspect Component For Cause
1ST AND 2ND GEARS ONLY 2-3 Shift Solenoid (305) D Stuck OFF, solenoid leaking,
electrical.
Possible
P ibl CCodes:
d
2-3 Shift Valve (307) D Stuck in downshifted position.
756 2-3 Shift Solenoid
Performance Direct Clutch D Failed clutch (released).

THIRD AND FOURTH GEARS ONLY

Condition Inspect Component For Cause
3RD AND 4TH GEARS ONLY 2-3 Shift Solenoid (305) D Stuck ON, solenoid plugged,
electrical.
Possible Codes:
756 2-3 Shift Solenoid 1-2 and 2-3 Shift Valves D Both stuck in upshifted position.
Performance

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 71

FIRST AND FOURTH GEARS ONLY

Condition Inspect Component For Cause
1ST AND 4TH GEARS ONLY 1-2 Shift Solenoid (305) D Stuck ON, electrical, solenoid
plugged.
Possible Codes:
751 1-2 Shift Solenoid
Performance Fault

SECOND AND THIRD GEARS ONLY

Condition Inspect Component For Cause
2ND AND 3RD GEARS ONLY 1-2 Shift Solenoid (305) D Stuck OFF, electrical, solenoid
leaking.
Possible Codes:
751 1-2 Shift Solenoid
Performance Fault

NO PARK
Condition Inspect Component For Cause
NO PARK Parking Lock Actuator D Rod bent or damaged.
Assembly (807) D Spring binding or broken.
D Rod not attached to detent lever.
Detent Roller and Spring (804) D Bolt not torqued, loose.
D Bent, damaged.
Detent Lever (806) D Damaged, loose (manual shift pin
missing).
Manual Valve (800) D Misaligned, manual valve to
detent lever link bent.
Park Lock Gear (659) D Damaged teeth, splines
damaged.
Parking Lock Pawl (663) D Damaged, tooth broken.
Park Pawl Spring (662) D Broken, missing.
Shift Linkage D Misadjusted.

RATCHETING NOISE
Condition Inspect Component For Cause
RATCHETING NOISE Parking Pawl (663) D Return spring damaged, weak or
misassembled.

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5A -- 72 4T40-E AUTOMATIC TRANSAXLE

NO ENGINE BRAKING; ALL MANUAL RANGES

Condition Inspect Component For Cause
NO ENGINE Coast Clutch D No apply/slipping.
COMPRESSION BRAKING: D Piston and Seal Assembly (504) D Binding, cracked, leaking.
ALL MANUAL RANGES D Clutch Plates (508, 509) D Friction worn, splines broken.
D Springs (505) D Binding.
D Direct & Coast Clutch Housing D Damaged, cracked, fluid feed
and Input Shaft (502) holes restricted.
D Housing Retainer and D Missing, loose.
Ball Assembly
Coast Clutch Fluid Routing
D Valve Body D Porosity, misaligned, loose, fluid
Gaskets and Spacer Plate restriction, fluid leak across
Channel Plate & Gasket channels.
Driven Sprocket Support
D Driven Sprocket Support Seals D Leaking.
D Input Shaft (502) D Seals leaking.
D Sleeve damaged, misaligned.
Oil Level/Line Pressure D Low (See Low Line Pressure).
3-4 Shift Valve (319) D Stuck in 4th gear position.
(No coast clutch apply).
Manual Valve/Shift Linkage (800) D Misaligned.

NO ENGINE BRAKING; MANUAL SECOND - SECOND GEAR

Condition Inspect Component For Cause
NO ENGINE Coast Clutch D No apply/slipping. (See No
COMPRESSION BRAKING: Engine Compression Braking:
MANUAL SECOND - SECOND All Ranges).
GEAR
Intermediate/4th Band (100) D No apply/slipping (See No 4th
Gear: Intermediate/4th Band -
Possible Codes: No apply).
1810 TFP Malfunction
TFP (13) D Leaking, inoperative.
A/T OSS (62) D Reads 0 mph.

NO ENGINE BRAKING; MANUAL FIRST - FIRST GEAR

Condition Inspect Component For Cause
NO ENGINE Coast Clutch D No apply/slipping. (See No
COMPRESSION BRAKING: Engine Compression Braking:
MANUAL FIRST - FIRST GEAR All Ranges).
LO & Reverse Servo D No apply/slipping (See No
Possible Codes:
Reverse: LO & Reverse Band -
1810 TFP Malfunction No apply/slipping).
TFP (13) D Leaking, inoperative.
#1 Checkball (LO/PRN) D Missing.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 73

DRIVES IN NEUTRAL
Condition Inspect Component For Cause
DRIVES IN NEUTRAL Forward Clutch (Drives Forward) D Not releasing.
Reverse Clutch D Both not releasing.
LO & Reverse Servo D Misaligned.
(Drives in Reverse)

NO GEAR SELECTION
Condition Inspect Component For Cause
NO GEAR SELECTIONS Manual Valve to Detent Lever D Broken, missing.
Link (802) D Disconnected from manual valve.
Manual Valve to Link Clip (801) D Disconnected.
Manual Valve (800) D Stuck.
Shift Linkage D Disconnected.
Valve Body D Blocked fluid channels.
Channel Plate and Case

SHIFT INDICATOR INDICATES WRONG GEAR SELECTION

Condition Inspect Component For Cause
SHIFT INDICATOR INDICATES Indicator Linkage D Misadjusted.
WRONG GEAR SELECTION
Detent Spring and Roller D Broken, missing.
Assembly (804) D Bolt loose.
Manual Valve D Not connected to detent lever.

FLUID LEAKS
Condition Inspect Component For Cause
FLUID LEAKS Refer to Fluid Leak Diagnosis in this
section.

FLUID FOAMING
Condition Inspect Component For Cause
FLUID FOAMING Fluid D Degraded fluid.
D Contaminate (Antifreeze).
D Transaxle overfilled.
Cooler Lines D Plugged.
Transaxle Oil Filter (85) D Clogged.
D Cracked.
Filter Seal (84) D Leaking.
Side Cover Seal (6) D Damaged.
Engine D Overheated.
Vehicle D Overloaded.
Oil Level Control Valve (86) D Damaged, loose.

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5A -- 74 4T40-E AUTOMATIC TRANSAXLE

VIBRATION
Condition Inspect Component For Cause
VIBRATION Torque Converter (55) D Out of balance.
D Internal failure.
Transaxle/Engine D Misaligned.
Output (94)/Stub Shafts (58) D Out of balance.
D Bushings worn or damaged.
Turbine Shaft (39) D Worn bushings.
D Out of balance.

NOISE
Condition Inspect Component For Cause
NOISE -

In All Ranges or a WHINE which Torque Converter (55) D Verify noise internal to torque
may be rpm or load sensitive or converter by placing left foot on
ceases when TCC engages. brake with gear or selector in
Drive and momentarily stall
engine. Torque converter noise
increases under load.
A high pitch WHINE which will Oil Pump System D Verify noise internal to oil pump
intensify with engine rpm or is oil during preliminary oil pressure
pressure sensitive. check. An increase in line
pressure will vary an oil pump
noise.
A popping noise similar to popcorn Oil Pump System D Pump cavitation - indicated by
popping. bubbles in fluid.
D Transaxle fluid filter for seam
leak.
D Transaxle fluid filter seal for
proper positioning or cut seal,
A BUZZ or high frequency rattle Trace cooler pipes and check for D Verify pressure buzz by watching
sound. binding or contact at the radiator for a needle vibration on the
other than the cooler pipe pressure gauge. (Road test may
connectors. be necessary.)
A WHINE or GROWL that Drive Link Assembly System
increases and fades with vehicle Verify noise from sprockets and/or
speed and is most noticeable drive link assembly (chain) by
under light acceleration. placing left foot on brake and
moving gear selector from P (Park)
or R (Reverse).
If noise stops check items below:
Drive Chain (36) D Stretched.
Drive Sprocket (37) D Teeth broken or sheared.
Driven Sprocket (91) D Bearing surfaces nicked or
scored.
D Bearing race or roller bearing
surfaces on gear support inner
bearing rough or pitted.
D Bearing damage.
Drive Sprocket Support (43) D Bearing outer race support rough
Driven Sprocket Support (95) or nicked.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 75

Noise (Cont’d)
Condition Inspect Component For Cause
NOISE - (Continued)

A final drive noise or HUM, is most Final Drive Gear Set (116) D Worn, planet pinions or washers.
noticeable under light
g throttle Final Drive Internal Gear (118) D Worn, tooth damage.
accele atio a
acceleration and/or
d/o tturns.
s
Differential Carrier (116) D Gears worn or pitted.
Differential Side Gears (709) D Thrust washer damage.
Noise in 1st,, 2nd,, 3rd or 4th. Final Drive Sun Gear (115) D Gear worn or damage.
Final Drive Pinions (707) D Gears worn or damaged.
Noise only in certain gear ranges. Check Range Reference Chart.
Determine power flow and
applicable components that may be
causing noise.

NO TCC/SLIPPING/SOFT APPLY
Condition Inspect Component For Cause
NO TCC/SLIPPING/SOFT APPLY TCC Solenoid (335) D Stuck OFF.
D O-ring leaking.
Possible Codes: D No voltage to solenoid.
703 Brake Switch Malfunction D Poor electrical connection.
712 Trans Fluid Temp Sensor
Circuit - Low Input Wiring Harness (11) D Pinched wire (electrical short).
713 Trans Fluid Temp Sensor D Damaged electrical connector.
Circuit - High Input
716 Input Speed Sensor Circuit TCM D No signal to solenoid.
- Range/Performance
717 Input Speed Sensor Circuit Brake Switch D Not functioning (open).
- Malfunction
722 Output Speed Sensor - Pressure Regulator Valve D Stuck.
Malfunction
723 Output Speed Sensor - Torque Converter (55) D Internal failure.
Intermittent/Erratic
726 Engine Speed Sensor TCC Fluid Circuits D Leaks (Refer to Oil Flow
Circuit - Intermittent Diagrams).
727 Engine Speed Sensor Low D Plugged release exhaust orifice.
742 TCC Circuit Stuck ON
751 1-2 Shift Solenoid TCC-Regulated APply Valve (339) D Stuck in TCC release position.
Performance TCC Control Valve (334)
756 2-3 Shift Solenoid
Performance TCC Feed Limit Valve D Stuck.
1810 TFP Malfunction
1812 Trans Fluid Overtemp Fluid Level or Pressure D Low.
1887 TCC Release Switch
Malfunction Cooler Lines D Plugged.

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5A -- 76 4T40-E AUTOMATIC TRANSAXLE

NO TCC RELEASE
Condition Inspect Component For Cause
NO TCC RELEASE TCC Solenoid (335) D Internal failure.
D Fluid exhaust plugged.
D External ground.
Torque Converter (55) D Internal failure.
TCC-Regulated Apply Valve (339) D Stuck in TCC apply position.
TCC Control Valve (334)

TCC APPLY WITH COLD ENGINE

Condition Inspect Component For Cause
TCC APPLY WITH COLD ENGINE Engine Coolant Temp Sensor D Malfunction.

TCC SHUDDER
Condition Inspect Component For Cause
TCC SHUDDER Refer to TCC Shudder Diagnosis in
this section.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 77

DIAGNOSTIC TROUBLE CODE DIAGNOSIS

DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION

DTC Description Power Lamp Default Action

P0218 Transmission Fluid Off D DTC P0218 will be stored in TCM memory.
Overtemperature D Freeze shift adapts.
P0711 Transmission Fluid Flashing D DTC P0711 will be stored in TCM memory.
Temperature Sensor Circuit D Freeze shift adapts.
Range/Performance D Transmission default temperature calculated
based on engine coolant temperature,
manifold air temperature, and engine run time.
P0712 Transmission Fluid Off D DTC P0712 will be stored in TCM memory.
Temperature Sensor Circuit D Freeze shift adapts.
Low Input D Transmission default temperature calculated
based on engine coolant temperature,
manifold air temperature, and engine run time.
P0713 Transmission Fluid Off D DTC P0713 will be stored in TCM memory.
Temperature Sensor Circuit D Freeze shift adapts.
High Input D Transmission default temperature calculated
based on engine coolant temperature,
manifold air temperature, and engine run time.
P0716 Input Speed Sensor Circuit Flashing D DTC P0716 will be stored in TCM memory.
Range/Performance D Inhibit TCC engagement.
D Freeze shift adapts.
D Maximum line pressure.
P0717 Input Speed Sensor Circuit Flashing D DTC P0717 will be stored in TCM memory.
No Signal D Inhibit TCC engagement.
D Freeze shift adapts.
D Maximum line pressure.
P0719 Brake Switch Circuit Low Off D DTC P0719 will be stored in TCM memory.
P0722 Automatic Transmission Output Flashing D DTC P0722 will be stored in TCM memory.
Speed Sensor (A/T OSS) Low D Freeze shift adapts.
Input D Maximum line pressure.
D Output speed calculated from input speed,
engine speed, and commanded gear.
P0723 Automatic Transmission Output Flashing D DTC P0723 will be stored in TCM memory.
Speed Sensor (A/T OSS) D Freeze shift adapts.
Intermittent D Commands maximum line pressure.
D Output speed calculated from input speed,
engine speed, and commanded gear.
P0724 Brake Switch Circuit High Off D DTC P0724 will be stored in TCM memory.
P0726 Engine Speed Sensor Circuit Flashing D DTC P0726 will be stored in TCM memory.
Intermittent D Inhibit TCC engagement.
D Freeze shift adapts.
P0727 Engine Speed Sensor Circuit Flashing D DTC P0727 will be stored in TCM memory.
Low Input D Inhibit TCC engagement.
D Freeze shift adapts.
D Maximum line pressure.

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5A -- 78 4T40-E AUTOMATIC TRANSAXLE

Diagnostic Trouble Code (DTC) Identification (Cont’d)

DTC Description Power Lamp Default Action

P0730 Incorrect Gear Ratio Off D DTC P0730 will be stored in TCM memory.
D Maximum line pressure.
D Freeze shift adapts.
P0741 Torque Converter Clutch Circuit Flashing D DTC P0741 will be stored in TCM memory.
Stuck Off D Freeze shift adapts.
D Inhibit TCC engagement.
P0742 Torque Converter Clutch Circuit Flashing D DTC P0742 will be stored in TCM memory.
Stuck On D Freeze shift adapts.
D TCC commanded for 1-2, 2-3 and 3-4 shifts.
P0748 Pressure Control Solenoid Off D DTC P0748 will be stored in TCM memory.
Circuit Electrical D Freeze shift adapts.
D Maximum line pressure.
P0751 1-2 Shift Solenoid Performance Flashing D DTC P0751 will be stored in TCM memory.
D Freeze shift adapts.
D Inhibit TCC engagement.
D Maximum line pressure.
D Commands soft landing to 2nd gear.
P0756 2-3 Shift Solenoid Performance Flashing D DTC P0756 will be stored in TCM memory.
D Freeze shift adapts.
D Inhibit TCC engagement.
D Maximum line pressure.
D Immediate landing to 2nd gear.
P1810 Automatic Transmission Fluid Flashing D DTC P1810 will be stored in TCM memory.
Pressure Manual Valve D Freeze shift adapts.
Position Switch (TFP Val. D Assume D4 shift pattern.
Position Sw.) Malfunction
D Inhibit TCC engagement.
D Assume D2 braking pressure.
P1811 Maximum Adapt and Long Shift Off D DTC P1811 will be stored in TCM memory.
D Maximum line pressure.
D Freeze shift adapts.
P1814 Torque Converter Overstress Off D DTC P1814 will be stored in TCM memory.
P1887 TCC Release Switch Circuit Flashing D DTC P1887 will be stored in TCM memory.
Malfunction D Freeze shift adapts.
D Inhibit TCC engagement.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 79

BLANK

DAEWOO J-100 BL2 / BL3

5A -- 80 4T40-E AUTOMATIC TRANSAXLE

A103A034

DIAGNOSTIC TROUBLE CODE (DTC) P0218

TRANSMISSION FLUID OVERTEMPERATURE

Circuit Description When the TCM detects a high transmission fluid temper-
The transmission fluid pump is constantly circulating ature for a long period of time, then DTC P0218 sets.
fluid through the torque converter. Hot fluid leaving the Conditions For Setting The DTC
converter flows through the transmission cooler lines to
D Transmission temperature is greater than 130_C
the oil cooler located in the vehicle radiator. From the
(260_F) for 15 minutes.
cooler, fluid returns to the transmission.
D No TFT Sensor DTC(s) P0711, P0712 or P0713.
Lube 1 fluid flows through the input shaft to lubricate
transmission components in the front of the transmis- Action Taken When The DTC Sets
sion. Lube 2 fluid circuit is fed by line pressure at the D TCM will NOT flash the Power Lamp.
pressure regulator valve. This fluid flows through the oil
D Freeze shift adapts from being updated.
feed pipes and into the forward clutch support. Lube 2
fluid provides lubrication to the rear components of the D DTC P0218 will be stored in TCM memory.
transmission.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 81
Conditions For Clearing The DTC Test Description
D Transmission temperature is less than or equal to The numbers below refer to the step numbers on the
129_C (260_F) for five seconds. diagnostic chart.
D History DTC(s) can be cleared by using a Scan Tool. 1. This step checks for possible low fluid level causing
D Check the transmission cooling system. high transmission fluid temperatures.
D Question the owner for the possibility of vehicle over- 2. This step checks for possible transmission cooling re-
loading, exceeding trailer towing limits or towing in strictions.
overdrive. 5. This step checks for possible torque converter failure.

DTC P0218 - Transmission Fluid Overtemperature

Step Action Value(s) Yes No
1. Install the scan tool.
2. Ignition ON, engine OFF.
3. Record then clear DTC(s).
1 -
Has the transmission fluid checking procedure been Go to Fluid
performed? Checking
Refer to Transmission Fluid Checking Procedure. Go to Step 2 Procedure
Inspect the engine and transmission cooling system
for air flow restrictions or blockage, debris, or
2 damaged cooler lines. -
Was the problem found and corrected? Go to Step 6 Go to Step 3
Check the valve body for a stuck or leaking pressure
3 regulator (PR) valve. -
Was the problem found and corrected? Go to Step 6 Go to Step 4
Inspect the oil feedtubes for restrictions or leaking
4 seals. -
Was the problem found and corrected? Go to Step 6 Go to Step 5
Check for torque converter stator damage.
5 Refer to Torque Converter Diagnosis. - -
Was the problem found and corrected? Go to Step 6
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
6 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 82 4T40-E AUTOMATIC TRANSAXLE

B203A004

DIAGNOSTIC TROUBLE CODE (DTC) P0711

TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR CIRCUIT
RANGE/PERFORMANCE

Circuit Description D TCC slip speed is greater than 300 rpm for 409
The Automatic Transmission Fluid Temperature (TFT) seconds, cumulative.
sensor assembly is a thermistor and is part of the D Engine Coolant Temperature is greater than 70_C
Automatic Transmission Fluid Pressure Manual Valve (158_F).
Position Switch Assembly (TFP Val. Position Sw.). The D Engine Coolant Temperature has changed by more
Transmission Control Module (TCM) supplies a 5-volt than 50_ since start up.
reference signal to the sensor on circuit 506. When
D All of the above must be true and one of the following
transmission fluid is cold, the sensor resistance is high
fail cases must be true:
and the TCM senses a high signal voltage. As the trans-
mission fluid warms, the sensor resistance lowers and Fail Case 1
the TCM senses lower voltage. The TCM uses the TFT D Transmission temperature has not changed more
readings to control Torque Converter Clutch (TCC) line than 1.5_C (2_F) since start-up.
pressure adjustments, and temperature compensated
shifts. Fail Case 2
When the TCM detects one of the following unusual D Transmission temperature changes more than 20_C
conditions, then DTC P0711 sets. (36_F) within 200 milliseconds.
1. An unrealistically large change in transmission tem- Action Taken When The DTC Sets
perature.
D The TCM will flash the Power Lamp after two consec-
2. A value which remains constant for a period of time in utive ignition cycles with a failure reported.
which a measurable amount of change is expected.
D DTC P0711 is stored in the TCM history.
Conditions For Setting The DTC D The PCM freezes shift adapts from being updated.
D Engine is running. D The TCM calculates transmission temperature based
D System voltage is between 9-16 volts. on engine coolant temperature, intake manifold air
D No VSS codes P0722 or P0723. temperature and engine run time.
D No ISS codes P0716 or P0717. Conditions For Clearing The DTC
D Vehicle speed is greater than 8 km/h (5 mph) for 409 Fail Case 1
seconds, cumulative.
D The TFT changes by more than 2.25 degrees for at
D Transmission start up temperature is between * 40_ least 5 seconds.
and 21_C (* 40_ and 69.8_F).

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 83
Fail Case 2 D If diagnosing for a possible intermittent short or open
D The TFT does not change by more than 20 degrees condition, move or massage the wiring harness while
within 0.200 secondfor a periodof at least 11 seconds. observing test equipment for a change.
D History DTC(s) can be cleared by using a Scan Tool. Test Description
Diagnostic Aids The numbers below refer to the step numbers on the
diagnostic chart.
D Inspect the wiring for poor electrical connections at
the TCM and at the transmission 20-way connector. 5. This step checks for an intermittent short or open
Look for possible bent, backed out, deformed or condition in the engine wiring harness. The test light
damaged terminals. Check for weak terminal tension is used as a resistor in the circuit.
as well. Also check for chafed wire that could short to 6. This step determines if the TCM or the TFT sensor is
bare metal or other wiring. Inspect for broken wire in- causing a steady, unchanging TFT reading.
side the insulation.

DTC P0711 - Transmission Fluid Temperature (TFT) Sensor Circuit Range/Performance

Step Action Value(s) Yes No
Perform the transmission fluid checking procedure. Go to
Refer to Transmission Fluid Checking Procedure. - Transmission
1
Did you perform the fluid checking procedure? Fluid Checking
Go to Step 2 Procedure
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to
the ON position.
3. Record then clear DTC(s).
4. Select TFT on the scan tool.
5. Drive the vehicle and observe the scan tool for
2 either of the following conditions: -
D The TFT does not change more than 1.5_C
(2.7_F) in 80 seconds since start-up.
D The TFT changes more than 20_C (36_F) in
0.200 seconds 14 times within 7 seconds (un- Go to
realistic change). Diagnostic
Did either of the fail conditions occur? Go to Step 3 Aids
Did the scan tool display a condition in which the
3 TFT does not change by more than the specified
value in 80 seconds since start-up? 1.5_C (2.7_F) Go to Step 5 Go to Step 4
1. Turn the engine OFF.
2 Disconnect the transmission 20-way connector.
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4. Using the J 35616 Connector Test Adapter Kit,
connect a test light from terminal L to terminal M.
4
5. Turn the ignition switch to the ON position.
6. While observing the scan tool display, move or
massage the engine wiring harness from the TCM
connectors to the transmission 20-way connector.
Does the TFT change by more than the specified
value? 20_C (36_F) Go to Step 6 Go to Step 7
1. Turn the ignition OFF.
2 Disconnect the transmission 20-way connector.
5 3. Turn the ignition switch to the ON position.
Did the scan tool display a condition in which the
TFT does not change by more than the specified
value in 80 seconds since start-up? 1.5_C (2.7_F) Go to Step 10 Go to Step 9

DAEWOO J-100 BL2 / BL3

5A -- 84 4T40-E AUTOMATIC TRANSAXLE

DTC P0711 - Transmission Fluid Temperature (TFT) Sensor Circuit

Range/Performance (Cont’d)
Step Action Value(s) Yes No
Inspect circuits 506 and 507 of the engine wiring
harness for an intermittent open or short condition. -
6 Repair the circuits if necessary.
Was a problem found? Go to Step 11 Go to Step 10
Inspect the automatic transmission wiring harness
for an intermittent short to ground or a short together -
7 on circuits 506 or 507.
Was a problem found? Go to Step 8 Go to Step 9
Replace the automatic transmission wiring harness.
8
Is the replacement complete? - Go to Step 11 -
Replace the TFT sensor (this is part of the TFP
9 Valve Position Switch). - -
Is the replacement complete? Go to Step 11
Replace the TCM.
10 Refer to TCM Replacement. - -
Is the replacement complete? Go to Step 11
1. After the repair, use a scan tool ‘‘Clear Info’’
function and road test the vehicle.
11 2 Review the ‘‘DTC Info’’. - Begin
Has the last test failed or is the current DTC Diagnosis Repair verified,
displayed? again exit DTC Chart

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 85

BLANK

DAEWOO J-100 BL2 / BL3

5A -- 86 4T40-E AUTOMATIC TRANSAXLE

B203A004

DIAGNOSTIC TROUBLE CODE (DTC) P0712

TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR CIRCUIT LOW INPUT
Circuit Description Diagnostic Aids
The Automatic Transmission Fluid Temperature (TFT) D Inspect the wiring for poor electrical connections at
sensor assembly is a thermistor and is part of the the TCM and at the transmission 20-way connector.
Automatic Transmission Fluid Pressure Manual Valve Look for possible bent, backed out, deformed or
Position Switch (TFP Val. Position Sw.). The TCM sup- damaged terminals. Check for weak terminal tension
plies a 5 volt reference signal to the sensor on circuit as well. Also check for chafed wires that could short
506. When transmission fluid is cold, the sensor resis- to bare metal or other wiring. Inspect for broken wire
tance is high and the TCM will sense a high signal inside the insulation.
voltage. As the transmission fluid warms, the sensor re- D If diagnosing for a possible intermittent short or open
sistance lowers and the TCM senses lower voltage. The condition, move or massage the wiring harness while
TCM uses the TFT readings to control Torque observing test equipment for a change.
Converter Clutch (TCC) apply and release, line pressure
D DTC P0712 couldset if the vehicle or transmission has
adjustments, and temperature compensated shifts.
been exposedto temperature above 150_C (300_F).
When the TCM detects a continuous short to ground in
the TFT signal circuit or the TFT sensor, then DTC Test Description
P0712 sets. The numbers below refer to the step numbers on the
diagnostic chart.
Conditions For Setting The DTC
2. This test checks the TCM’s ability to detect an open
D Ignition is ON.
circuit.
D TFT voltage is less then 0.33 volts for 10 seconds.
3. This test checks the TFT Sensor for correct resistance.
Action Taken When The DTC Sets
D Freeze shift adapts from being updated.
D Transmission default temperature will be calculated
based on engine coolant temperature, manifold air
temperature, and engine run time.
D DTC P0712 will be stored in TCM memory.
Conditions For Clearing The DTC
D When TFT voltage is greater than 0.33 volts for
10 seconds for three consecutive ignition cycles.
D History DTC(s) can be cleared by using a Scan Tool.
A103A036

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 87

DTC P0712 - Transmission Fluid Temperature (TFT) Sensor Circuit Low Input
Step Action Value(s) Yes No
1.Install the scan tool.
2.Ignition ON, engine OFF.
3.Record then clear DTC(s).
1 4.Select Scan Tool Data List Trans Fluid Temp
Sensor. Go to
Does the scan tool display transmission fluid Diagnostic
temperature as shown? 152_C Go to Step 2 Aids
1. Ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTC(s) will set).
2
3. Ignition ON.
Does the scan tool display transmission fluid
temperature as shown? * 40_C Go to Step 4 Go to Step 3
Check circuit 506 from the engine side of the
transmission 20-way connector to the TCM
3 connector for a short to ground. -
Was the problem found and corrected? Go to Step 8 Go to Step 5
Using J 35616 Connector Test Adapter Kit, connect
an ohmmeter from terminal L to terminal M. 20_C (68_F)
4 (Refer to Transmission Connector EndView.) 3106-3923W
Are ohm readings within range shown for the given 100_C (212_F)
transmission temperature range? 164-190W Go to Step 5 Go to Step 6
Replace the TCM.
5 - -
Is the replacement complete? Go to Step 8
Check circuit 506 from the transmission 20-way
connector to the TFT sensor connector for a short
6 to ground. -
Was the problem found and corrected? Go to Step 8 Go to Step 7
Replace the TFP Val. Position Sw.
Refer to Automatic Transmission Fluid Pressure
7 - -
Manual Valve Position Switch Replacement.
Is the replacement complete? Go to Step 8
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
8 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 88 4T40-E AUTOMATIC TRANSAXLE

B203A004

DIAGNOSTIC TROUBLE CODE (DTC) P0713

TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR CIRCUIT HIGH INPUT
Circuit Description Diagnostic Aids
The Automatic Transmission Fluid Temperature (TFT) D Inspect the wiring for poor electrical connection at the
Sensor Assembly is a thermistor and is part of the TCM and at the transmission 20-way connector. Look
Automatic Transmission Fluid Pressure Manual Valve for possible bent, backed out, deformed or damaged
Position Switch (TFP Val. Position Sw.). The TCM sup- terminals. Check for weak terminal tension as well.
plies a 5 volt reference signal to the sensor on circuit Also check for chafed wires that could short to bare
506. When transmission fluid is cold, the sensor resis- metal or other wiring. Inspect for broken wire inside
tance is high and the TCM will sense a high signal the insulation.
voltage. As the transmission fluid warms, the sensor re- D If diagnosing for a possible intermittent short or open
sistance lowers and the TCM senses lower voltage. The condition, move or massage the wiring harness while
TCM uses the TFT readings to control Torque observing test equipment for a change.
Converter Clutch (TCC) apply and release, line pressure
adjustments, and temperature compensated shifts. Test Description
When the TCM detects a continuous open or short to The numbers below refer to the step numbers on the
power in the TFT signal circuit or the TFT sensor, then diagnostic chart.
DTC P0713 sets. 2. This test checks the wiring from the transmission
20-way connector to the TCM for an open or short.
Conditions For Setting The DTC
3. This test checks circuit 507 from the TCM to the
D Ignition is ON.
transmission connector.
D TFT voltage is greater than 4.92 volts for 30 seconds.
Action Taken When The DTC Sets
D DTC P0713 will be stored in TCM memory.
D Freeze shift adapts from being updated.
D Transmission default temperature will be calculated
based on engine coolant temperature, manifold air
temperature, and engine run time.
Conditions For Clearing The DTC
D When the TFT voltage is less than 4.92 volts for
30 seconds for three consecutive ignition cycles.
D History DTC(s) can be cleared by using a Scan Tool. A103A037

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 89

DTC P0713 - Transmission Fluid Temperature (TFT) Sensor Circuit High Input
Step Action Value(s) Yes No
1.Install the scan tool.
2.Ignition ON, engine OFF.
3.Record then clear DTC(s).
1 4.Select Scan Tool Data List Trans Fluid Temp
Sensor. Go to
Does the scan tool display transmission fluid Diagnostic
temperature as shown? * 40_C Go to Step 2 Aids
1. Ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTC(s) will set).
3. Using J 35616 Connector Test Adapter Kit,
2 install a fused jumper wire from terminal L to
terminal M.
4. Ignition ON, engine OFF.
Does the scan tool display transmission fluid
temperature as shown? 152_C Go to Step 6 Go to Step 3
Using J 35616 Connector Test Adapter Kit, jump
terminal L to a good ground.
3
Does the scan tool display transmission fluid
temperature as shown? 152_C Go to Step 6 Go to Step 4
Check circuit 506 from the engine side of the
transmission 20-way connector to connector for an
4 open. -
Was the problem found and corrected? Go to Step 8 Go to Step 5
Replace the TCM.
5 - -
Is the replacement complete? Go to Step 8
Check circuit 506 and circuit 507 from the
transmission 20-way connector to the TFT sensor
6 for an open. -
Was the problem found and corrected? Go to Step 8 Go to Step 7
Replace the TFP Val. Position Sw.
Refer to Automatic Transmission Fluid Pressure
7 - -
Manual Valve Position Switch Replacement.
Is the replacement complete? Go to Step 8
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
8 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 90 4T40-E AUTOMATIC TRANSAXLE

B203A005

DIAGNOSTIC TROUBLE CODE (DTC) P0716

INPUT SPEED SENSOR CIRCUIT RANGE/PERFORMANCE

Circuit Description D Freeze shift adapts from being updated.

Transmission input speed is provided to the Transmis- D TCM commands maximum line pressure.
sion Control Module (TCM) by the Automatic Trans-
Conditions For Clearing The DTC
mission Input (Shaft) Speed Sensor (A/T ISS), which is a
Permanent Magnet (PM) generator. The sensor mounts D Input speed is greater than 50 rpm.
into the transmission case and maintains a slight air D When the input speed has changed less than 300 rpm
gap between the sensor and the drive sprocket. The PM in 0.3 seconds for three consecutive ignition cycles.
generator produces an AC voltage as the drive sprocket D No Input Speed Sensor DTC P0717.
rotor teeth pass in front of the sensor’s magnetic field. D History DTC(s) can be cleared by using a Scan Tool.
The AC voltage level increases as the speed of the
turbine shaft increases. The TCM then converts the AC Diagnostic Aids
voltage into a digital signal. This digital signal is then used D This diagnostic test checks for an input speed sensor
by the TCM to determine actual turbine speed. The TCM circuit problem. If the engine is running and the ve-
uses input speed to calculate torque converter slip speed hicle is moving above a certain speed, then the input
andgear ratios. speed must be non-zero.
When the TCM detects an unrealistic large change in in- D Inspect the wiring for poor electrical connections at
put speed, then DTC P0716 sets. the TCM and at the transmission 20-way connector.
Look for possible bent, backed out, deformed or dam-
Conditions For Setting The DTC aged terminals. Check for weak terminal tension as
D Input speed change is greater than 1300 rpm in well. Also check for chafed wires that could short to
0.8 seconds. bare metal or other wiring. Inspect for broken wire in-
D No Input Speed Sensor DTC P0717. side the insulation.
D No TPS DTC P1791. D If diagnosing for a possible intermittent short or open
condition, move or massage the wiring harness while
D No VSS DTC(s) P0722 or P0723. observing test equipment for a change.
D No 1-2 shift solenoid DTC P0751.
Test Description
D Engine running.
The numbers below refer to the step numbers on the
D TP angle is greater then 15%. diagnostic chart.
D Vehicle speed is greater than 8 km/h (5 mph). 2. This test checks the speedsensor for correct resistance.
Action Taken When The DTC Sets 6. This test verifies the wiring from the transmission
D DTC P0716 will be stored in TCM memory. 20-way connector to the TCM, and tests the ability of
the A/T ISS to produce an AC current.
D TCM inhibits TCC engagement.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 91

DTC P0716 - Input Speed Sensor Circuit Range/Performance

Step Action Value(s) Yes No
1. Install the scan tool.
2. Turn the ignition switch to the ON position.
3. Engine not running.
4. Record then clear the DTC(s).
1
5. Start the engine.
6. Select scan tool Trans ISS.
Does the scan tool display transmission input speed Go to
more than shown? 500 rpm Diagnostic Aids Go to Step 2
1. Ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTC(s) will set).
3. Install J 39775 Jumper Harness to the
2
transmission 20-way connector.
4. Using J 35616 Connector Test Adapter Kit,
connect an ohmmeter between terminals S and V.
Does the ohmmeter display resistance as shown? 615-835W Go to Step 6 Go to Step 3
Check circuit 511 from the transmission 20-way
connector to the A/T ISS for an open or short to -
3 ground.
Was the condition found and corrected? Go to Step 10 Go to Step 4
Check circuit 513 from the transmission 20-way
connector to the A/T ISS for an open or short to -
4 ground.
Was the condition found and corrected? Go to Step 10 Go to Step 5
Replace the A/T ISS.
Refer to Automatic Transmission Input (Shaft) - -
5
Speed Sensor Replacement.
Is the replacement complete? Go to Step 10
1. Ignition OFF.
2. Disconnect J 39775 Jumper Harness and
reconnect the 20-way connector.
3. Disconnect the TCM connector.
4. Using J 35616 Connector Test Adapter Kit,
6
connect a voltmeter from terminals C11 to
terminal D10.
5. Select the A/C volts.
6. Crank the engine. 0.150 mV
Does the voltmeter display volts greater than shown? (50 Hz) Go to Step 9 Go to Step 7
Check circuit 511 from the engine 20-way connector to
7 the TCM connector for an open or short to ground. -
Was the condition found and corrected? Go to Step 10 Go to Step 8
Check circuit 513 from the engine 20-way connector to
8 the TCM connector for an open or short to ground. - -
Was the condition found and corrected? Go to Step 10
Replace the TCM.
9 Refer to TCM Replacement. - -
Is the replacement complete? Go to Step 10
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
10 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 92 4T40-E AUTOMATIC TRANSAXLE

B203A005

DIAGNOSTIC TROUBLE CODE (DTC) P0717

INPUT SPEED SENSOR CIRCUIT NO SIGNAL

Circuit Description D TCM inhibits TCC engagement.

Transmission input speed is provided to the Transmis- D Freeze shift adapts from being updated.
sion Control Module (TCM) by the Automatic Trans-
Conditions For Clearing The DTC
mission Input (Shaft) Speed Sensor (A/T ISS), which is a
Permanent Magnet (PM) generator. The sensor mounts D When turbine speed is greater than 120 rpm for three
into the transmission case and maintains a slight air seconds for three consecutive ignition cycles.
gap between the sensor and the drive sprocket. The PM D History DTC(s) can be cleared by using a Scan Tool.
generator produces an AC voltage as the drive sprocket
Diagnostic Aids
rotor teeth pass in front of the sensor’s magnetic field.
The AC voltage level increases as the speed of the D This diagnostic test checks for an input speed sensor
turbine shaft increases. The TCM then converts the AC circuit problem. If the engine is running and the ve-
voltage into a digital signal. This digital signal is then used hicle is moving above a certain speed, then the input
by the TCM to determine actual turbine speed. The TCM speed must be non-zero.
uses input speed to calculate torque converter slip speed D Inspect the wiring for poor electrical connections at
andgear ratios. the TCM and at the transmission 20-way connector.
When the TCM detects a low input speed when the ve- Look for possible bent, backed out, deformed or dam-
hicle has a large output speed, then DTC P0717 sets. aged terminals. Check for weak terminal tension as
well. Also check for chafed wires that could short to
Conditions For Setting The DTC bare metal or other wiring. Inspect for broken wire in-
D No TFP Val. Position Sw. DTC P1810. side the insulation.
D No VSS DTC(s) P0722 or P0723. D If diagnosing for a possible intermittent short or open
D Engine running. condition, move or massage the wiring harness while
observing test equipment for a change.
D TFP Val. Position Sw. is indicating transmission is not
in Park or Neutral. Test Description
D Turbine input speed is less than 100 rpm for five The numbers below refer to the step numbers on the
seconds. diagnostic chart.
D Vehicle speed is greater than 8 km/h (5 mph). 2. This test checks the speed sensor for correct resist-
ance.
Action Taken When The DTC Sets
6. This test verifies the wiring from the transmission
D DTC P0717 will be stored in TCM memory.
20-way connector to the TCM, and tests the ability of
D TCM commands maximum line pressure. the A/T ISS to produce an AC current.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 93

DTC P0717 - Input Speed Sensor Circuit No Signal

Step Action Value(s) Yes No
1. Install the scan tool.
2. Turn the ignition switch to the ON position.
3. Engine not running.
4. Record then clear the DTC(s).
1
5. Start the engine.
6. Select scan tool Trans ISS.
Does the scan tool display transmission input speed Go to
more than shown? 500 rpm Diagnostic Aids Go to Step 2
1. Ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTC(s) will set).
3. Install J 39775 Jumper Harness to the
2
transmission 20-way connector.
4. Using J 35616 Connector Test Adapter Kit,
connect an ohmmeter between terminals S and V.
Does the ohmmeter display resistance as shown? 615-835W Go to Step 6 Go to Step 3
Check circuit 511 from the transmission 20-way
connector to the A/T ISS for an open or short to -
3 ground.
Was the condition found and corrected? Go to Step 10 Go to Step 4
Check circuit 513 from the transmission 20-way
connector to the A/T ISS for an open or short to -
4 ground.
Was the condition found and corrected? Go to Step 10 Go to Step 5
Replace the A/T ISS.
Refer to Automatic Transmission Input (Shaft) - -
5
Speed Sensor Replacement.
Is the replacement complete? Go to Step 10
1. Ignition OFF.
2. Disconnect J 39775 Jumper Harness and
reconnect the 20-way connector.
3. Disconnect the TCM connector.
4. Using J 35616 Connector Test Adapter Kit,
6
connect a voltmeter from terminals C11 to
terminal D10.
5. Select the A/C volts.
6. Crank the engine. 0.150 mV
Does the voltmeter display volts greater than shown? (50 Hz) Go to Step 9 Go to Step 7
Check circuit 511 from the engine 20-way connector to
7 the TCM connector for an open or short to ground. -
Was the condition found and corrected? Go to Step 10 Go to Step 8
Check circuit 513 from the engine 20-way connector to
8 the TCM connector for an open or short to ground. -
Was the condition found and corrected? Go to Step 10 Go to Step 9
Replace the TCM.
9 Refer to TCM Replacement. - -
Is the replacement complete? Go to Step 10
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
10 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 94 4T40-E AUTOMATIC TRANSAXLE

B203A006

DIAGNOSTIC TROUBLE CODE (DTC) P0719

BRAKE SWITCH CIRCUIT LOW

Circuit Description Diagnostic Aids

The brake switch is used to indicate brake pedal status D Ask customer about driving habits and/or unusual
to the Transmission Control Module (TCM). The brake traffic conditions, such as heavy stop and go driving.
switch is a normally-open switch. Applying the brake D Check brake switch for proper adjustment.
pedal closes the switch, supplying voltage to the TCM.
D Inspect the wiring for poor electrical connections
Releasing the brake pedal interrupts voltage to the
at the TCM and at the brake switch connector. Look
TCM. When the TCM sees 12 volts at the brake switch
for possible bent, backed out, deformed or damaged
input, the TCM de-energizes the Torque Converter
terminals. Check for weak terminal tension as well.
Clutch Solenoid Valve (TCC Sol. Val.).
Also check for chafed wires that could short to bare
When the TCM detects an open brake switch during de- metal or other wiring. Inspect for broken wire inside
celerations, then DTC P0719 sets. the insulation.
Conditions For Setting The DTC D If diagnosing for a possible intermittent short or open
This DTC will set if the TCM detects an open brake condition, move or massage the wiring harness while
switch/circuit (0 volts) during vehicle deceleration and observing test equipment for a change.
the following conditions occur six consecutive times: Test Description
D Vehicle speed is greater than 32 km/h for six seconds; The numbers below refer to the step numbers on the
then vehicle speed is between 8 and 32 km/h for four diagnostic chart.
seconds; then vehicle speedis less than 8 km/h. 1. Disconnecting the brake switch connector, and jump-
Action Taken When The DTC Sets ing the circuit, and observing a status change, isolates
the brake switch as the source for setting the DTC.
D DTC P0719 will be stored in TCM memory.
2. If the brake switch circuit is shorted to ground, the
Conditions For Clearing The DTC ignition feed fuse would open.
D When the TCM has seen a change in the brake 4. If the brake switch is adjusted properly, then the
switch state and three consecutive ignition cycles. brake switch must be replaced.
D History DTC(s) can be cleared by using a Scan Tool. 7. Replacement of the TCM only after the brake switch
and all related circuitry have been properly inspected
or repaired.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 95

DTC P0719 - Brake Switch Circuit Low

Step Action Value(s) Yes No
1. Install the scan tool.
2. Turn the ignition switch to the ON position.
3. Engine not running.
4. Record then clear the DTC(s).
5. Select scan tool Brake Switch. -
1
6. Disconnect the brake switch connector.
7. Install a fuse jumper from terminal B to terminal C
of the brake switch connector.
Did the brake switch status change from ‘‘Open’’ to
‘‘Close’’? Go to Step 4 Go to Step 2
Remove and inspect the brake switch ignition feed
2 fuse for an open. -
Was the fuse open? Go to Step 3 Go to Step 6
Inspect the brake switch feed circuit for a short to
3 ground. - -
Was the condition found and corrected? Go to Step 8
Inspect the brake switch for proper adjustment.
4
Was the condition found and corrected? - Go to Step 8 Go to Step 5
Replace the brake switch.
5 Refer to Brake Switch Replacement. - -
Is the replacement complete? Go to Step 8
Inspect circuit 534 for an open.
6
Was the condition found and corrected? - Go to Step 8 Go to Step 7
Replace the TCM.
7 Refer to TCM Replacement. - -
Is the replacement complete? Go to Step 8
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
8 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 96 4T40-E AUTOMATIC TRANSAXLE

B203A007

DIAGNOSTIC TROUBLE CODE (DTC) P0722

AUTOMATIC TRANSMISSION OUTPUT SPEED SENSOR (A/T OSS) LOW INPUT
Circuit Description D TCM freezes shift adapts from being updated.
Vehicle speed is provided to the Transmission Control D TCM commands maximum line pressure.
Module (TCM) and Cruise Control Module (Optional D TCM calculates output speed based on input speed,
Equipment) by the Automatic Transmission Output engine speed, and commanded gear.
(Shaft) Speed Sensor (A/T OSS), which is a Permanent
D DTC P0722 will be stored in TCM memory.
Magnet (PM) generator mounted to the transmission
case. The PM generator produces an AC voltage as the Conditions For Clearing The DTC
speed sensor rotor teeth pass in front of the sensor’s D The TCM will turn the Power Lamp off after the trans-
magnetic field. The AC voltage level increases as the mission output speed is greater than 500 rpm for
speed of the vehicle increases. The TCM then converts three seconds and three consecutive ignition cycles.
the AC voltage into a digital signal. The TCM uses the D History DTC(s) can be cleared by using a Scan Tool.
vehicle speed to determine shift timing, TCC apply, TCC
Diagnostic Aids
release, and gear ratio calculations.
D Condition may be intermittent. Check for loose output
When the TCM detects a low vehicle output speed when
speed sensor mounting or poor sensor connection.
the vehicle has a large engine speed in a drive gear,
then DTC P0722 sets. D Inspect for a damaged output speed sensor or trans-
mission rotor teeth.
Conditions For Setting DTC
D Inspect the wiring for poor electrical connections at the
D Transmission not in P (Park) or N (Neutral).
TCM, the Cruise Control Module, the Splice Pack, the
D No MAP DTC. A/T OSS. Look for possible bent, backed out, de-
D No A/T ISS DTC(s) P0716 or P0717. formed or damaged terminals. Check for weak termi-
D No TP DTC P1791. nal tension as well. Also check for chafed wires that
D No TFP Val. Position Sw. DTC P1810. could short to bare metal or other wiring. Inspect for
D TP is greater than 10%. broken wire inside the insulation.
D MAP is greater than 10 kPa. D If diagnosing for a possible intermittent short or open
D Transmission input speed is greater than 1000 rpm. condition, move or massage the wiring harness while
observing test equipment for a change.
D Engine speed is greater than 6000 rpm.
D Output speed is less than 100 rpm. Test Description
D All the above conditions are met for five seconds. The numbers below refer to the numbered steps on the
diagnostic chart.
Action Taken When The DTC Sets
2. This test checks the A/T OSS for correct resistance.
D TCM will flash the Power Lamp after two consecutive
3. This tests the A/T OSS ability to produce an AC
trips with a failure reported.
current and the integrity of the wiring to the TCM.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 97

DTC P0722 - Automatic Transmission Output Speed Sensor (A/T OSS) Low Input
Step Action Value(s) Yes No
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to
the ON position.
3. Record then clear the DTC(s).
Notice: In order to avoid damage to the drive
axles, support the lower control arms in the normal
horizontal position. Do not run the vehicle in gear
1 with the wheels hanging down at full travel. -
4. Raise and support the drive wheels.
5. Start and idle the engine.
6. Place the transmission in Drive.
With the drive wheels rotating, does the
transmission output speed increase when the wheel Go to
speed increases? Diagnostic Aids Go to Step 2
1. Turn the ignition OFF.
2. Disconnect the A/T OSS connector at the
transmission.
2 3. Using J 35616 Connector Test Adapter Kit,
connect the ohmmeter from terminal A to
terminal B of the A/T OSS.
Is the resistance within the specified range? 1530-1870W Go to Step 3 Go to Step 5
1. Reconnect the A/T OSS connector.
2. Disconnect the TCM connector.
3. Connect a voltmeter between terminals A12 and
B12.
3
4. Select the AC volts.
5. Rotate the drive wheels.
6. Observe the voltmeter display.
Is the voltage greater than the specified value? 0.5 V Go to Step 6 Go to Step 4
Inspect circuits 503/A and 519/B for an open, short
to ground, or short together. Go to
4 -
Refer to Troubleshooting Procedures. Diagnostic
Was the condition found and corrected? Go to Step 7 Aids
Replace the A/T OSS.
5 Refer to Sensor Replacement. - -
Is the replacement complete? Go to Step 7
Replace the TCM/Cruise Control Module.
Refer to TCM Replacement & Cruise Control Module
6
Replacement.
Is the replacement complete? - Go to Step 7 -
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
7 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 98 4T40-E AUTOMATIC TRANSAXLE

DTC P0722 - Automatic Transmission Output Speed Sensor (A/T OSS) Low Input
Step Action Value(s) Yes No
If equipped with Cruise Control System
1. At first, disconnect the W/Harness of Cruise
Control Module (connection “C”).
2. If do not check a fault, reconnect the W/Harness
connection “C”.
8 3. Disconnect the Cruise Control Module and TCM.
4. Connect a voltmeter between terminal 10 and 5.
5. Select the AC volts.
6. Rotate the drive wheels.
7. Observe the voltmeter display. 0.5 V Go to Step 6 Go to Step 4
Is the voltage greater than the specified value?

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 99

BLANK

DAEWOO J-100 BL2 / BL3

5A -- 100 4T40-E AUTOMATIC TRANSAXLE

B203A007

DIAGNOSTIC TROUBLE CODE (DTC) P0723

AUTOMATIC TRANSMISSION OUTPUT SPEED SENSOR (A/T OSS)
INTERMITTENT

Circuit Description D The TCM calculates ouput speed based on input

Vehicle speed is provided to the Transmission Control speed, engine speed, and commanded gear.
Module (TCM) and Cruise Control Module (Optional D DTC P0723 will be stored in TCM memory.
Equipment) by the Automatic Transmission Output
Conditions For Clearing The DTC
(Shaft) Speed Sensor (A/T OSS), which is a Permanent
Magnet (PM) generator mounted to the transmission D The TCM will turn the Power Lamp off after the
case. The PM generator produces an AC voltage as the output speed sensor has not failed this DTC for three
speed sensor rotor teeth pass in front of the sensor’s consecutive ignition cycles.
magnetic field. The AC voltage level increases as the D History DTC(s) can be cleared by using a Scan Tool.
speed of the vehicle increases. The TCM then converts
Diagnostic Aids
the AC voltage into a digital signal. The TCM uses the
vehicle speed to determine shift timing, TCC apply, TCC D Condition may be intermittent. Check for loose output
release, and gear ratio calculations. speed sensor mounting or poor sensor connection.
When the TCM detects an unrealistic large change in D Inspect for a damaged output speed sensor or trans-
vehicle speed, then DTC P0723 sets. mission rotor teeth.
D Inspect the wiring for poor electrical connections at the
Conditions For Setting The DTC TCM, the Cruise Control Module, the Splice Pack, the
D Engine running. A/T OSS. Look for possible bent, backed out, de-
D No TFP Val. Position Sw. DTC P1810. formed or damaged terminals. Check for weak termi-
D Time since last manual gear select lever change is nal tension as well. Also check for chafed wires that
greater than 3 seconds. could short to bare metal or other wiring. Inspect for
broken wire inside the insulation.
D A decrease in output speed greater than 900 rpm in
park or neutral or a decrease greater than 1300 rpm D If diagnosing for a possible intermittent short or open
in drive. condition, move or massage the wiring harness while
observing test equipment for a change.
Action Taken When The DTC Sets
Chart Test Description
D TCM will flash the Power Lamp after two consecutive The numbers below refer to the numbered steps on the
trips with a failure reported. diagnostic chart.
D TCM freezes shift adapts from being updated.
2. This test checks the A/T OSS for correct resistance.
D TCM commands maximum line pressure.
3. This tests the A/T OSS ability to produce an AC
current and the integrity of the wiring to the TCM.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 101

DTC P0723 - Automatic Transmission Output Speed Sensor (A/T OSS) Intermittent
Step Action Value(s) Yes No
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to
the ON position.
3. Record then clear the DTC(s).
Notice: In order to avoid damage to the drive
axles, support the lower control arms in the normal
horizontal position. Do not run the vehicle in gear
1 with the wheels hanging down at full travel. -
4. Raise and support the drive wheels.
5. Start and idle the engine.
6. Place the transmission in Drive.
With the drive wheels rotating, does the
transmission output speed increase when the wheel Go to
speed increases? Diagnostic Aids Go to Step 2
1. Turn the ignition OFF.
2. Disconnect the A/T OSS connector at the
transmission.
2 3. Using J 35616 Connector Test Adapter Kit,
connect the ohmmeter from terminal A to
terminal B of the A/T OSS.
Is the resistance within the specified range? 1530-1870W Go to Step 3 Go to Step 5
1. Reconnect the A/T OSS connector.
2. Disconnect the TCM connector.
3. Connect a voltmeter between terminals A12 and
B12.
3
4. Select the AC volts.
5. Rotate the drive wheels.
6. Observe the voltmeter display.
Is the voltage greater than the specified value? 0.5 V Go to Step 6 Go to Step 4
Inspect circuits 503/A and 519/B for an open, short
to ground, or short together. Go to
4 -
Refer to Troubleshooting Procedures. Diagnostic
Was the condition found and corrected? Go to Step 7 Aids
Replace the A/T OSS.
5 Refer to Sensor Replacement. - -
Is the replacement complete? Go to Step 7
Replace the TCM/Cruise Control Module.
Refer to TCM Replacement & Cruise Control Module
6
Replacement.
Is the replacement complete? - Go to Step 7 -
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
7 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 102 4T40-E AUTOMATIC TRANSAXLE

DTC P0723 - Automatic Transmission Output Speed Sensor (A/T OSS) Intermittent
Step Action Value(s) Yes No
If equipped with Cruise Control System
1. At first, disconnect the W/Harness of Cruise
Control Module (connection “C”).
2. If do not check a fault, reconnect the W/Harness
connection “C”.
8 3. Disconnect the Cruise Control Module and TCM.
4. Connect a voltmeter between terminal 10 and 5.
5. Select the AC volts.
6. Rotate the drive wheels.
7. Observe the voltmeter display. 0.5 V Go to Step 6 Go to Step 4
Is the voltage greater than the specified value?

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 103

BLANK

DAEWOO J-100 BL2 / BL3

5A -- 104 4T40-E AUTOMATIC TRANSAXLE

B203A006

DIAGNOSTIC TROUBLE CODE (DTC) P0724

BRAKE SWITCH CIRCUIT HIGH

Circuit Description Diagnostic Aids

The brake switch is used to indicate brake pedal status D Ask customer about driving habits and/or unusual
to the Transmission Control Module (TCM). The brake traffic conditions, such as heavy stop and go driving.
switch is a normally-open switch. Applying the brake D Check brake switch for proper adjustment.
pedal closes the switch, supplying voltage to the TCM.
D Inspect the wiring for poor electrical connections at the
Releasing the brake pedal interrupts voltage to the
TCM and at the brake switch. Look for possible bent,
TCM. When the TCM sees 12 volts at the brake switch
backed out, deformed or damaged terminals. Check
input, the TCM de-energizes the Torque Converter
for weak terminal tension as well. Also check for
Clutch Solenoid Valve (TCC Sol. Val.).
chafed wires that could short to bare metal or other
When the TCM detects a closed brake switch during ac- wiring. Inspect for broken wire inside the insulation.
celerations, then DTC P0724 sets.
D If diagnosing for a possible intermittent short or open
Conditions For Setting The DTC condition, move or massage the wiring harness while
This DTC will set if the TCM detects a closed brake observing test equipment for a change.
switch/circuit (12 volts) during vehicle acceleration and Test Description
the following conditions occur six consecutive times:
The numbers below refer to the step numbers on the
D Vehicle speed is less than 8 km/h; then vehicle speed diagnostic chart.
is between 8 and 32 km/h for four seconds; then ve- 1. Disconnecting the brake switch connector, and ob-
hicle speed is greater than 32 km/h for six seconds.
serving a status change, isolates the brake switch as
Action Taken When The DTC Sets the source for setting the DTC.
D DTC P0724 will be stored in TCM memory. 2. If the brake switch is adjusted properly, then the
brake switch must be replaced.
Conditions For Clearing The DTC
3. This step will inspect circuit 534 for a short to power
D When the TCM has seen a change in the brake if the status on the scan tool never changed from
switch state and three consecutive ignition cycles. “Closed” to “Open.” If a short is found, make the ap-
D History DTC(s) can be cleared by using a Scan Tool. propriate repair.
4. Replacement of the TCM only after the brake switch
and all related circuitry have been properly inspected
or repaired.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 105

DTC P0724 - Brake Switch Circuit High

Step Action Value(s) Yes No
1. Install the scan tool.
2. Turn the ignition switch to the ON position.
3. Engine not running.
4. Record then clear the DTC(s). -
1
5. Select scan tool Brake Switch.
6. Disconnect the brake switch connector.
Did the brake switch status change from ‘‘Closed’’ to
‘‘Open’’? Go to Step 2 Go to Step 3
Replace the brake switch.
2 Refer to Brake Switch Replacement. - -
Is the replacement complete? Go to Step 5
Inspect circuit 534 for being short to power.
3 -
Was the condition found and corrected? Go to Step 5 Go to Step 4
Replace the TCM.
4 Refer to TCM Replacement. - -
Is the replacement complete? Go to Step 5
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
5 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 106 4T40-E AUTOMATIC TRANSAXLE

B203A008

DIAGNOSTIC TROUBLE CODE (DTC) P0726

ENGINE SPEED SENSOR CIRCUIT INTERMITTENT

Circuit Description Conditions For Clearing The DTC

The ECM receives a signal from the ignition system to D The TCM will turn the Power Lamp off after the en-
determine engine speed. The TCM sends five volts on gine speed is greater than 200 rpm for one second.
circuit 515 to the ECM. The ECM pulses this circuit to D History DTC(s) can be cleared by using a Scan Tool.
ground at the rate of 33 Hz per 1000 rpm. The TCM uses
the rpm signal to calculate torque converter slip and Diagnostic Aids
TCC apply rate. D Inspect the wiring for poor electrical connections at
When the TCM detects a loss of engine input speed, the TCM and at the ECM. Look for possible bent,
then DTC P0726 sets. backed out, deformed or damaged terminals. Check
for weak terminal tension as well. Also check for
Conditions For Setting The DTC chafed wires that could short to bare metal or other
D Engine is running. wiring. Inspect for broken wires inside the insulation.
D Engine speed is greater than 250 rpm. D If diagnosing for a possible intermittent short or open
D Engine rpm changes more than 1000 rpm within one condition, move or massage the wiring harness while
second. observing test equipment for a change.

Action Taken When The DTC Sets Test Description

D TCM inhibits TCC engagement. The numbers below refer to the step numbers on the
diagnostic chart.
D TCM freezes shift adapts from being updated.
1. This step checks for a five volt signal from the TCM.
D The TCM will flash the Power Lamp.
2. This step checks for a short to power (12V) on circuit
515.
4. This step checks for a short to power (12V) on circuit
515.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 107

DTC P0726 - Engine Speed Sensor Circuit Intermittent

Step Action Value(s) Yes No
1. Install the scan tool.
2. Ignition ON, engine OFF.
3. Record then clear the DTC(s).
4. Ignition OFF.
5. Disconnect the ECM connector.
1
6. Ignition ON.
7. Set voltmeter to DC volts.
8. Connect a voltmeter from terminal B13 of the
ECM connector to a good ground.
Is voltage reading as shown? 5.0 V Go to Step 2 Go to Step 5
2 Is voltage greater than shown? u 5.0 V Go to Step 3 Go to Step 7
1. Connect a test light from terminal B13 of the ECM
connector to a good ground.
3 - -
2. Disconnect the TCM connector.
Is the test light ON? Go to Step 4
Check circuit 515 for a short to power.
4 - -
Was the condition found and corrected? Go to Step 8
Check circuit 515 from the TCM to ECM connector
5 terminal B13 for an open or short to ground. -
Was the condition found and corrected? Go to Step 8 Go to Step 6
Replace the TCM.
6
Is the replacement complete? - Go to Step 8 -
Replace the ECM.
7
Is the replacement complete? - Go to Step 8 -
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
8 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 108 4T40-E AUTOMATIC TRANSAXLE

B203A008

DIAGNOSTIC TROUBLE CODE (DTC) P0727

ENGINE SPEED SENSOR CIRCUIT LOW INPUT

Circuit Description D TCM commands maximum line pressure.

The ECM receives a signal from the ignition system to D TCM inhibits TCC engagement.
determine engine speed. The TCM sends five volts on
Conditions For Clearing The DTC
circuit 515 to the ECM. The ECM pulses this circuit to
ground at the rate of 33 Hz per 1000 rpm. The TCM uses D The TCM will turn the Power Lamp off when engine
the rpm signal to calculate torque converter slip and speed is greater than 250 rpm for three consecutive
TCC apply rate. ignition cycles.
The TCM detects low engine rpm when the vehicle has D History DTC(s) can be cleared by using a Scan Tool.
a large input speed, throttle position, and vehicle speed Diagnostic Aids
in a drive gear range, then DTC P0727 sets.
D Inspect the wiring for poor electrical connections at
Conditions For Setting The DTC the TCM and the ECM. Look for possible bent,
D Transmission not in P (Park) or N (Neutral). backed out, deformed or damaged terminals. Check
for weak terminal tension as well. Also check for
D Engine is running.
chafed wires that could short to bare metal or other
D TP is greater than 20%. wiring. Inspect for broken wire inside the insulation.
D Engine speed is less than 200 rpm. D If diagnosing for a possible intermittent short or open
D Output speed is greater than 600 rpm. condition, move or massage the wiring harness while
D Input speed is greater than 600 rpm. observing test equipment for a change.
D No input speed sensor DTC(s) P0716 or P0717. Test Description
D No engine speed DTC P0726 The numbers below refer to the step numbers on the
D No vehicle speed DTC(s) P0722 or P0723. diagnostic chart.
D No TFP Val. Position Sw. DTC P1810 1. This step checks for a five volt signal from the TCM.
D No TP DTC P1791. 2. This step checks for a short to power (12V) on circuit
515.
D All the above conditions are met for five seconds.
4. This step checks for a short to power (12V) on circuit
Action Taken When The DTC Sets 515.
D TCM will flash the Power Lamp.
D Freeze shift adapts from being updated.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 109

DTC P0727 - Engine Speed Sensor Circuit Low Input

Step Action Value(s) Yes No
1. Install the scan tool.
2. Ignition ON, engine OFF.
3. Record then clear the DTC(s).
4. Ignition OFF.
5. Disconnect the ECM connector.
1
6. Ignition ON.
7. Set voltmeter to DC volts.
8. Connect a voltmeter from terminal B13 of the
ECM connector to a good ground.
Is voltage reading as shown? 5.0 V Go to Step 2 Go to Step 5
2 Is voltage greater than shown? u 5.0 V Go to Step 3 Go to Step 7
1. Connect a test light from terminal B13 of the ECM
connector to a good ground.
3 - -
2. Disconnect the TCM connector.
Is the test light ON? Go to Step 4
Check circuit 515 for a short to power.
4 - -
Was the condition found and corrected? Go to Step 8
Check circuit 515 from the TCM to ECM connector
5 terminal B13 for an open or short to ground. -
Was the condition found and corrected? Go to Step 8 Go to Step 6
Replace the TCM.
6
Is the replacement complete? - Go to Step 8 -
Replace the ECM.
7
Is the replacement complete? - Go to Step 8 -
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
8 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 110 4T40-E AUTOMATIC TRANSAXLE

LO
1-2 2-3 2ND DIRECT FOR-
2ND INT./4T REVERSE COAST INPUT LO/REV. ROLLER
RANGE GEAR SHIFT SHIFT ROLLER CLUTC WARD
CLUTCH H BAND CLUTCH CLUTCH SPRAG BAND CLUTC
SOL SOL CLUTCH H CLUTCH
H
PARK N ON OFF Applied
REV R ON OFF Applied Applied
NEU N ON OFF Applied
1st ON OFF Holding Applied Holding
Over-
2nd OFF OFF Applied Holding Holding Applied
running
D Over- Over-
3rd OFF ON Applied* Holding Applied Applied
running running
Over- Over-
4th ON ON Applied* Applied Applied Applied*
running running
1st ON OFF Applied Holding Applied Holding
Over-
2nd OFF OFF Applied Holding Applied Holding Applied
3 running
Over- Over-
3rd OFF ON Applied* Applied Holding Applied Applied
running running
1st ON OFF Applied Holding Applied Holding
Over-
2nd OFF OFF Applied Holding Applied Applied Holding Applied
2 running
Over- Over-
3rd** OFF ON Applied* Applied Holding Applied Applied
running running
1st ON OFF Applied Holding Applied Applied Holding
1 Over-
2nd*** OFF OFF Applied Holding Applied Applied Holding Applied
running

ON =SOLENOID ENERGIZED
OFF =SOLENOID DE-ENERGIZED.
* =APPLIED WITH NO LOAD.
** =MANUAL SECOND - THIRD GEAR IS ONLY AVAILABLE ABOVE APPROXIMATELY 100 km/h (62 mph).
*** =MANUAL FIRST - SECOND GEAR IS ONLY AVAILABLE ABOVE APPROXIMATELY 60 km/h (37 mph).
NOTE: MANUAL FIRST - THIRD GEAR IS ALSO POSSIBLE AT HIGH VEHICLE SPEED AS A SAFETY FEATURE.

DIAGNOSTIC TROUBLE CODE (DTC) P0730

INCORRECT GEAR RATIO

Circuit Description D Transmission not in P (Park) or N (Neutral).

The Transmission Control Module (TCM) calculates gear D TP is greater than 15%.
ratio based on the transmission input and output speed D MAP is greater than 10 kPa.
sensor readings. The TCM compares the known trans-
D Vehicle speed is greater than 16 km/h (10 mph).
mission gear ratio to calculated ratio for the particular
gear range selected. D Transmission temperature is greater than * 10_C
(14_F).
When the TCM detects an unknown transmission gear
ratio, then DTC P0730 sets. D And one of the following conditions occur:
- Gear ratio is less than 2.87 or greater than 3.13 for
Conditions For Setting The DTC
seven seconds.
D No Output Speed Sensor DTC(s) P0722 or P0723. - Gear ratio is less than 1.54 or greater than 1.71 for
D No Input Speed Sensor DTC(s) P0716 or P0717. seven seconds.
D No TP Sensor DTC P1791. - Gear ratio is less than 0.91 or greater than 1.07 for
seven seconds.
D No TFP Val. Position Sw. DTC P1810.
- Gear ratio is less than 0.61 or greater than 0.72 for
D Engine running. seven seconds.
D Time since last manual gear select lever change is - Gear ratio is less than 2.02 or greater than 2.23 for
greater than three seconds. seven seconds.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 111
Action Taken When The DTC Sets D All the above conditions are met and any one of the
D TCM will command maximum line pressure. following occur:
D TCM will freeze shift adapts from being updated. - Gear ratio is between 2.87-3.13 for seven seconds.
- Gear ratio is between 1.54-1.71 for seven seconds.
D TCM will flash the Power Light.
- Gear ratio is between 0.91-1.07 for seven seconds.
D DTC P0730 will be stored in TCM memory. - Gear ratio is between 0.61-0.72 for seven seconds.
Conditions For Clearing The DTC - Gear ratio is between 2.02-2.23 for seven seconds.
D No Output Speed Sensor DTCs P0722 or P0723. D To cancel DTC fail actions, the fault must no longer ex-
ist andthe ignition must be cycledoff for five seconds.
D No Input Speed Sensor DTCs P0716 or P0717.
D History DTC(s) can be cleared by using a Scan Tool.
D No TP Sensor DTC P1791.
D No TFP Val. Position Sw. DTC P1810. Diagnostic Aids
D Engine running. D Check for intermittent input speed sensor or output
speed sensor circuit problems.
D Time since last manual gear select lever change is
greater than three seconds. D Check for possible incorrect calibration.
D Transmission not in Park or Neutral. Test Description
D TP is greater than 15%. The numbers below refer to the step numbers on the
D MAP is greater than 10 kPa. diagnostic chart.
D Vehicle speed is greater than 16 km/h (10 mph). 2. This step checks for possible low fluid level causing
slipping resulting in an undefined gear ratio.
D Transmission temperature is greater than * 10_C
(14_F). 3. This step checks for correct gear ratios for command-
ed gears.
4. This step checks for low line pressure.

DTC P0730 - Incorrect Gear Ratio

Step Action Value(s) Yes No
Visually inspect the transmission cooling system for
1 fluid leaks.
Was condition found and corrected? 5.0 V Go to Step 6 Go to Step 2
Has the transmission fluid checking procedure been Go to
performed? Transmission
2
- Fluid Check,
Go to Step 3 Procedures
1. Using the scan tool record each transmission drive
range.
2. Drive the vehicle in transmission gear ranges 1, 2,
3 3, and D with TP greater than 15% and vehicle 1st: 2.87-3.13
speed greater than 16 km/h (10 mph) for five 2nd: 1.54-1.71
seconds. 3rd: 0.91-1.07 Refer to
Does commandedgear ratio match ranges as shown? 4th: 0.61-0.72 Diagnostic Aids Go to Step 4
Perform line pressure check.
4 -
Was the condition found and corrected? Go to Step 6 Go to Step 5
Check for possible clutch slippage.
5 - -
Was the condition found and corrected? Go to Step 6
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
6 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 112 4T40-E AUTOMATIC TRANSAXLE

B203A009

DIAGNOSTIC TROUBLE CODE (DTC) P0741

TORQUE CONVERTER CLUTCH CIRCUIT STUCK OFF

Circuit Description D No VSS DTC(s) P0722 or P0723.

The Torque Converter Clutch Solenoid Valve (TCC Sol. D No TCC stuck on DTC P0742.
Valve) is a pulse width modulated solenoid. The Trans- D No TCC release switch DTC P1887.
mission Control Module (TCM) energizes the TCC Sol.
D Transmission is in 2, 3, or D.
Valve by grounding circuit 502. When vehicle operating
conditions are appropriate to apply the TCC, the TCM D Time since last manual gear select lever change is
begins the TCC Sol. Valve duty cycle at 68%. The TCM greater than three seconds.
then ramps the duty cycle up to 93% to achieve full TCC D TCM commands TCC ON.
apply pressure. D TP is greater than 12%.
When the TCC Sol. Valve is de-energized, the solenoid D Transmission fluid temperature is between 0_C and
blocks filtered 2-3 drive fluid and allows TCC signal fluid 120_C (32_F and 248_F).
to exhaust. When energized, the solenoid modulates fluid
D Commanded gear is greater than 1st gear.
into the TCC signal fluid circuit. When fully energized,
modulation stops and the solenoid blocks both 2-3 drive D TCC slip speedis 250 rpm or greater for five seconds.
fluidandTCC signal fluidfrom being exhausted. Action Taken When The DTC Sets
When the TCM detects a high TCC slip speed when the D The TCM will flash the Power Lamp after two consec-
TCC is commanded on, then DTC P0741 sets. utive trips with a failure reported.
Conditions For Setting The DTC D DTC P0741 will be stored in TCM memory.
D No TP DTC P1791. D TCM inhibits TCC engagement.
D No TFP Val. Position Sw. DTC P1810. D Freeze shift adapts from being updated.

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Conditions For Clearing The DTC Test Description
D The TCM will turn the Power Lamp off after DTC The numbers below refer to the step numbers on the
P0741 passes condition test. This DTC passes when diagnostic chart.
all conditions for setting the DTC, (except TCC slip is 1. This test looks for other DTC(s) that would set when
less than 50 rpm for three seconds) are met for three the feed circuit is open.
consecutive ignition cycles.
7. This tests the TCM ability to command the TCC Sol.
D History DTC(s) can be cleared by using a Scan Tool. Valve ON and OFF.
Diagnostic Aids 9. This tests for proper transmission component/circuit
D Inspect the wiring for poor electrical connections at resistance.
the TCM and at the transmission 20-way connector.
Look for possible bent, backed out, deformed or dam-
aged terminals. Check for weak terminal tension as
well. Also check for chafed wire that could short to
bare metal or other wiring. Inspect for broken wire in-
side the insulation.
D If diagnosing for a possible intermittent short or open
condition, move or massage the wiring harness while
observing test equipment for a change.

A103A037

DTC P0741 - Torque Converter Clutch Circuit Stuck Off

Step Action Value(s) Yes No
1. Install the scan tool.
2. Ignition ON, engine OFF.
1 -
3. Record then clear DTC(s).
Are DTCs P0751 and P0756 also set? Go to Step 2 Go to Step 5
1. Ignition OFF.
2. Inspect circuit 524 from the I/P fuse block to the
2 -
engine fuse block for an open.
Was the condition found? Go to Step 3 Go to Step 4
Repair short to ground in circuit 524.
3 -
Was the condition found? Go to Step 14 Go to Step 9
Repair open in circuit 524.
4 - -
Was the condition found and corrected? Go to Step 14
1. Ignition OFF.
2. Disconnect transmission 20-way connector
(additional DTC(s) will set).
3. Using J 35616 Connector Test Adapter Kit, -
5
connect a test light from terminal E to a good
ground. (See Connector View.)
4. Ignition ON, engine OFF.
Is test light ON? Go to Step 7 Go to Step 6
Check circuit 528 between terminal E on the
transmission connector and E9 on the engine fuse - -
6 block for an open. Go to Step 14
Was the problem found and corrected?

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5A -- 114 4T40-E AUTOMATIC TRANSAXLE

DTC P0741 - Torque Converter Clutch Circuit Stuck Off (Cont’d)

Step Action Value(s) Yes No
1. Connect a test light from terminal E to terminal T.
2. With the scan tool, command TCC Duty Cycle
7 100% and then 0%. -
Is test light ON when commanded 100% and OFF
when commanded 0%? Go to Step 9 Go to Step 8
Check circuit 502 for an open.
8 - Go to Step 12
Was the problem found and corrected? Go to Step 14
Using J 35616 Connector Test Adapter Kit, connect
an ohmmeter from terminal E to terminal T.
9 (See Transmission Connector View.)
Does ohmmeter display resistance as shown? 11 to 15 W Go to Step 13 Go to Step 10
Check circuit 528 and 502 from transmission
10 20-way connector to TCC Sol. Valve for an open. -
Was the condition found and corrected? Go to Step 14 Go to Step 11
Replace the TCC Sol. Valve.
11 - -
Is the replacement complete? Go to Step 14
Replace the TCM.
12 - -
Is the replacement complete? Go to Step 14
Repair TCC shift valve circuit.
Inspect for:
D Leak at TCC Sol. Valve.
D TCC regulator apply valve stuck in the release -
13 -
position.
D TCC control valve stuck in the release position.
D Plugged TCC Sol. Valve filter.
Is the repair complete? Go to Step 14
1. After the repair is complete, select scan tool
‘‘Clear Info’’ function and road test the vehicle.
14 2. Review the ‘‘DTC Info’’. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 115

BLANK

DAEWOO J-100 BL2 / BL3

5A -- 116 4T40-E AUTOMATIC TRANSAXLE

B203A014

DIAGNOSTIC TROUBLE CODE (DTC) P0742

TORQUE CONVERTER CLUTCH CIRCUIT STUCK ON

Circuit Description The TCC release switch is a normally-closed switch.

The Torque Converter Clutch Solenoid Valve (TCC Sol. Torque Converter release fluid pressure acts on the
Valve) is a pulse width modulated solenoid. The Trans- switch contact, opening the circuit, signaling the TCM
mission Control Module (TCM) energizes the TCC Sol. that the TCC is released. When the voltage on the circuit
Valve by grounding circuit 502. When vehicle operating is high, the TCM recognizes that the TCC is no longer
conditions are appropriate for TCC application, the TCM engaged.
begins the TCC duty cycle at approximately 68%. The When the TCM detects that the TCC release switch is
TCM then increases the duty cycle up to 93%, in order to closed when the TCC is commanded off, then DTC
achieve full TCC-apply pressure. P0742 sets.
When the TCC Sol. Valve is de-energized, the solenoid Conditions For Setting The DTC
blocks filtered 2-3 drive fluid, and allows TCC signal fluid
D No TCC release DTC P1887.
to exhaust. When energized, the solenoid modulates
fluid into the TCC signal fluid circuit. When fully ener- D No TP DTC P1791.
gized, modulation stops, and the solenoid blocks both D Engine running.
2-3 drive fluid and TCC signal fluid exhaust. D Time since last manual gear select lever change is
The Torque Converter Clutch (TCC) release switch is greater than three seconds.
part of the Automatic Transmission Fluid Pressure D TP is greater than 20%.
Manual Valve Position Switch (TFP Val. Position Sw.).
D TCC commanded off.
The TFP Val. Position Sw. is mounted to the transmis-
sion valve body. D TCC release switch is closed.
D All the above conditions met for eight seconds.

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Action Taken When The DTC Sets as well. Also check for chafed wires that could short
D The TCM will flash the Power Lamp. to bare metal or other wiring. Inspect for broken wire
inside the insulation.
D DTC P0742 will be stored in TCM memory.
D If diagnosing for a possible intermittent short or open
D Freeze shift adapts from being updated.
condition, move or massage the wiring harness while
D TCC commanded on in 2nd, 3rd, and 4th gears. observing test equipment for a change.
Condition For Clearing DTC Test Description
D The TCM will turn the Power Lamp off after DTC The numbers below refer to the step numbers on the
P0742 passes condition test. This DTC passes when diagnostic chart.
all conditions for setting the DTC are true, (except
2. This step tests for a TCC release switch status
TCC release switch is open when TCC is command-
change when the engine is running. If TCC release
ed off for three seconds) for three consecutive igni-
oil is present, the switch should be open.
tion cycles.
3. If you disconnect the transmission connector, the
D History DTC(s) can be cleared by using a Scan Tool.
TCM should recognize an open TCC Release
Diagnostic Aids switch. This indicates the wiring from the trans-
D Rapid fluctuation in line pressure could set a DTC mission connector to the TCM is OK.
P0742. 11. This step tests circuit 502 from the transmission
D Check for a possible pressure regulator problem. connector to the TFP Val. Position Sw. for a short to
ground.
D Check for possible high or low line pressure.
16. This step ensures that the TCC release switch is in
D Inspect the wiring for poor electrical connections at
good working condition.
the TCM and at the transmission 20-way connector.
Look for possible bent, backed out, deformed or 18. This step tests the TCC circuit for a mechanical or
damaged terminals. Check for weak terminal tension hydraulic problem.

DTC P0742 - Torque Converter Clutch Circuit Stuck On

Step Action Value(s) Yes No
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to
the ON position.
1
3. Record then clear the DTC(s). Go to
4. Select scan tool TCC Release switch. Diagnostic
Is the TCC Release Switch status as shown? Closed Go to Step 2 Aids
Start the engine
2
Is the TCC Release Switch status as shown? Open Go to Step 8 Go to Step 3
1. Ignition OFF.
2. Disconnect the transmission 20-way connector.
3 3. With the engine OFF, turn the ignition switch to
the ON position.
Is the TCC Release Switch status as shown? Open Go to Step 4 Go to Step 6
Inspect circuit 512 from the transmission 20-way
connector to the TFP Val. Position SW. for a short to
4 ground. -
Was the condition found? Go to Step 5 Go to Step 16
Repair the short to ground in circuit 512.
5 - -
Is the repair complete? Go to Step 20
Inspect circuit 512 from the transmission connector
6 to the TCM for a short to ground. -
Was the condition found? Go to Step 7 Go to Step 15

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5A -- 118 4T40-E AUTOMATIC TRANSAXLE

DTC P0742 - Torque Converter Clutch Circuit Stuck On (Cont’d)

Step Action Value(s) Yes No
Repair the short to ground in circuit 512.
7 - -
Is the repair complete? Go to Step 20
1. Install the J 39775 Jumper Harness to the engine
20-way connector.
2. Using the J 35616 Connector Test Adapter Kit,
8 -
connect a test lamp from battery power to
terminal T of the jumper harness.
Is the test lamp ON? Go to Step 9 Go to Step 11
Inspect circuit 502 from the engine 20-way
9 connector to the TCM for a short to ground. -
Was the condition found? Go to Step10 Go to Step 19
Repair the short to ground in circuit 502.
10 - -
Is the repair complete? Go to Step 20
1. Ignition OFF.
2. Disconnect the J 39775 Jumper Harness from the
engine 20-way connector.
3. Instal the J 39775 Jumper Harness to the
11 -
transmission 20-way connector.
4. Using the J 35616 from battery power to
terminal T.
Is the test lamp ON? Go to Step 12 Go to Step 18
Inspect circuit 502 from the transmission connector
to the Torque Converter Clutch Solenoid Valve
12 (TCC Sol. Valve) for a short ground. -
Was the condition found? Go to Step 13 Go to Step 14
Repair circuit 502 from the transmission connector
13 to the TCC Sol. Valve. - -
Is the repair complete? Go to Step 20
Inspect the TCC Sol. Valve for an internal short.
14 - -
Was the condition found? Go to Step 15
Replace the TCC Sol. Valve.
Refer to Torque Converter Clutch Solenoid Valve
15 - -
Replacement.
Is the replacement complete? Go to Step 20
1. Remove the TFP Val. Position Sw.
2. Inspect the TCC Release Switch for the following
conditions:
D A damaged or leaking seal.
16 - -
D Sediment or debris in the switch.
D Damaged switch contacts.
D Stuck switch contacts.
Were any of these conditions found? Go to Step 17
Replace the TFP Val. Position Sw.
Refer to Automatic Transmission Fluid Pressure
17 - -
Manual Valve Position Switch Replacement.
Is the replacement complete? Go to Step 20

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 119

DTC P0742 - Torque Converter Clutch Circuit Stuck On (Cont’d)

Step Action Value(s) Yes No
Inspect the TCC hydraulic circuit for the following
conditions:
D TCC PWM solenoid exhaust plugged.
D The TCC regulator apply valve stuck in the apply
position.
18 D The TCC control valve stuck in the apply position. - -
D The TCC feed limit valve stuck (this causes the
TCC feed limit pressure, and the TCC release
pressure to be low or nonexistent).
D A stuck pressure regulator valve.
Is the repair complete? Go to Step 20
Replace the TCM.
19 Refer to TCM Replacement. - -
Is the replacement complete? Go to Step 20
1. After the repair is complete, select scan tool
“Clear info” function and road test the vehicle.
20 2. Review the “DTC info”. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 120 4T40-E AUTOMATIC TRANSAXLE

B203A010

DIAGNOSTIC TROUBLE CODE (DTC) P0748

PRESSURE CONTROL SOLENOID CIRCUIT ELECTRICAL

Circuit Description Diagnostic Aids

The Pressure Control Solenoid Valve (PC Sol. Valve) D Inspect the wiring for poor electrical connections at
is used to regulate transmission line pressure. The PC the TCM and at the transmission 20-way connector.
Sol. Valve consists of an electrical connector, coil, arma- Look for possible bent, backed out, deformed or dam-
ture, regulating spring and a poppet valve. The PC Sol. aged terminals. Check for weak terminal tension as
Valve is attached to the upper control body. The TCM well. Also check for chafed wires that could short to
compares TP voltage, engine rpm and other inputs to de- bare metal or other wiring. Inspect for broken wire in-
termine the line pressure appropriate for a given load. side the insulation.
The TCM will regulate pressure by applying a varying D If diagnosing for a possible intermittent short or open
amperage to the PC Sol. Valve. The applied amperage condition, move or massage the wiring harness while
can vary from 0.1 to 1.0 amps. The TCM then monitors observing test equipment for a change.
the amperage at the return line.
D Extended engine cranking with a low battery could set
When the TCM detects a continuous open or short to DTC P0748.
ground in PC Sol. Valve circuit or the PC Solenoid Valve,
then DTC P0748 sets. Test Description
The numbers below refer to the step numbers on the
Conditions For Setting The DTC diagnostic chart.
D System voltage is 10-17 volts. 1. This test checks the ability of the TCM to command
Action Taken When The DTC Is Set the PC Sol. Valve.
D Freeze shift adapts from being updated. 2. This test checks internal transmission wiring and the
PC Sol. Valve for correct resistance.
D TCM commands maximum line pressure (0 Amps).
7. This test checks circuit 505 of the transmission
D DTC P0748 will be stored in TCM memory. wiring for a short to ground.
D TCM will NOT flash the Power Lamp. 8. This test checks circuit 505 from the engine 20-way
connector for a short to ground.
Conditions For Clearing The DTC
9. This test checks circuit 505 from the engine 20-way
D System voltage is 10-17 volts. connector to the TCM for an open.
D History DTC(s) can be cleared by using a Scan Tool. 10. This test checks circuit 504 from the engine 20-way
connector to the TCM for a short to ground.
11. This test checks circuit 504 from the engine 20-way
connector to the TCM for an open.

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A103A036 A103A037

DTC P0748 - Pressure Control Solenoid Circuit Electrical

Step Action Value(s) Yes No
1. Install the scan tool.
2. Record then clear DTC(s).
3. Start engine.
4. Select scan tool PC Solenoid.
1 5. Using the scan tool, apply 0.1 through 1.0 Amps
and observe the display.
Is the PC Act. Current Amp reading within Go to
specification of desired PC Ref. Current Amp Diagnostic
reading as shown? 0.16 Amps Aids Go to Step 2
1. Ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTC(s) will set).
2 3. Using J 35616 Connector Test Adapter Kit,
connect an ohmmeter from terminal C to
terminal D. (See Transmission Connector View.)
Does the ohmmeter display range as shown? 3 to 7 W Go to Step 7 Go to Step 3
3 Is the resistance value greater than shown? 7W Go to Step 4 Go to Step 5
Check circuit 504 and 505 for an open.
4 -
Was the condition found and corrected? Go to Step 19 Go to Step 9
5 Is the resistance value less than shown? 3W - Go to Step 6
Check circuit 504 and 505 for being shorted
6 together. -
Was the condition found and corrected? Go to Step 19 Go to Step 9
Connect an ohmmeter from terminal D to a good
7 ground.
Is the resistance value less than shown? ¦ 1000 W Go to Step 8 Go to Step 10
Check circuit 504 or 505 from transmission 20-way
8 connector to PC Sol. Valve for a short to ground. -
Is the resistance value less than shown? Go to Step 19 Go to Step 9
Replace the Pressure Control Solenoid Valve.
9 Refer to PC Sol. Valve Replacement. - -
Was the replacement completed? Go to Step 19

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5A -- 122 4T40-E AUTOMATIC TRANSAXLE

DTC P0748 - Pressure Control Solenoid Circuit Electrical (Cont’d)

Step Action Value(s) Yes No
1. Disconnect the TCM connector (additional DTC(s)
will set).
2. Using J 35616 Connector Test Adapter Kit,
10
connect an ohmmeter from terminal D to a good
ground. (See Connector View.)
Does the ohmmeter display resistance as shown? ¦ 10 W Go to Step 12 Go to Step 11
Check circuit 505 for a short to ground.
11 - -
Was the condition found and corrected? Go to Step 19
Using J 35616 Connector Test Adapter Kit, connect
an ohmmeter from terminal D of the connector to
12 TCM terminal C16.
Does the ohmmeter display resistance as shown? ¦ 10 W Go to Step 14 Go to Step 13
Check circuit 505 for an open.
13 - -
Was the condition found and connected? Go to Step 19
Using J 35616 Connector Test Adapter Kit, connect
an ohmmeter from terminal C of the connector to a
14 good ground.
Does the ohmmeter display resistance as shown? ¦ 10 W Go to Step 16 Go to Step 15
Check circuit 504 for a short to ground.
15 - -
Was the condition found and corrected? Go to Step 19
Using J 35616 Connector Test Adapter Kit, connect
an ohmmeter from terminal C of the connector to
16 TCM terminal C15.
Does the ohmmeter display resistance as shown? ¦ 10 W Go to Step 18 Go to Step 17
Check circuit 504 for an open.
17 - -
Was the condition found and corrected? Go to Step 19
Replace the TCM.
18 - -
Was the replacement completed? Go to Step 19
1. After the repair, use a scan tool “Clear Info.”
function an road test the vehicle.
19 2. Review the “DTC Info”. -
Has the last test failed or is a current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 123

BLANK

DAEWOO J-100 BL2 / BL3

5A -- 124 4T40-E AUTOMATIC TRANSAXLE

B203A011

DIAGNOSTIC TROUBLE CODE (DTC) P0751

1-2 SHIFT SOLENOID PERFORMANCE

Circuit Description D Vehicle speed above 8 km/h (5 mph).

The 1-2 Shift Solenoid Valve (1-2 SS Valve) is used D TP is greater than 8%.
to control fluid flow acting on the 1-2 shift valve. The so- All the above conditions are true and any one of the
lenoid is a normally open valve that is used in conjunction following conditions occur:
with the 2-3 Shift Solenoid Valve (2-3 SS Valve) to allow
D TCM commands 1st gear and 2nd gear ratio between
four different shifting combinations (Refer to Shift Sole-
1.54-1.71 is detected for 2 seconds.
noid Chart). The solenoid is attached to the valve body
within the transmission. Voltage is supplied directly to the D TCM commands 2nd gear and 1st gear ratio between
solenoid through the Transmission Control Module 2.87-3.13 is detected for 4 seconds.
(TCM). The TCM commands the solenoid ON or OFF by D TCM commands 3rd gear and 4th gear ratio between
providing a groundpath through circuit 500. 0.67-0.72 is detected for 5 seconds.
The Transmission Control Module (TCM) monitors the D TCM commands 4th gear and 3rd gear ratio between
actual gear ratio, and compares the actual gear ratio 0.93-1.05 is detected for 5 seconds.
with the commanded gear ratio. DTC P0751 sets under
Action Taken When The DTC Is Set
four conditions:
D TCM will flash the Power Lamp after two consecutive
D A stuck ON 1-2 SS Valve.
trips with a failure reported.
D A stuck OFF 1-2 SS Valve.
D Freeze shift adapts from being updated.
D A stuck ON 1-2 shift Valve.
D TCM inhibits TCC engagement.
D A stuck OFF 1-2 shift Valve.
D TCM commands maximum line pressure.
Conditions For Setting The DTC D TCM commands soft landing to 2nd gear.
D No Input Speed Sensor DTC(s) P0716 or P0717. D DTC P0751 will be stored in TCM memory.
D No TFP Val. Position Sw. DTC P1810.
Conditions For Clearing The DTC
D No TP Sensor DTC P1791.
D The TCM will turn the Power Lamp off after DTC
D No Vehicle Speed Sensor DTC(s) P0722 or P0723. P0751 passes condition test. This DTC passes when
D Engine running. all conditions for setting the DTC are met and the
D MAP is greater than 20 kPa. gear ratio matches the commanded gear for three
consecutive ignition cycles.
D Transmission not in Park, Neutral or Reverse.
D History DTC(s) can be cleared by using a Scan Tool.
D Transmission Fluid Temperature is greater than
* 10_C (14_F).

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 125
Diagnostic Aids
D If the DTC cannot be reset after clearing the code,
check for possible fluid contamination, plugged or re-
stricted oil circuit.
D Inspect the wiring for poor electrical connections at
the TCM and at the transmission 20-way connector.
Look for possible bent, backed out, deformed or dam-
aged terminals. Check for weak terminal tension as
well. Also check for chafed wires that could short to
bare metal or other wiring. Inspect for broken wire in-
side the insulation.
D If diagnosing for a possible intermittent short or open A103A037

condition, move or massage the wiring harness while

observing test equipment for a change.

Shift Solenoid Status Chart

1-2 Shift 2-3 Shift
Gear
Solenoid Valve Solenoid Valve
1st ON OFF
2nd OFF OFF
3rd OFF ON
4th ON ON

A103A036

DTC P0751 - 1-2 Shift Solenoid Performance

Step Action Value(s) Yes No
1. Install the scan tool.
2. Ignition ON, engine OFF.
1 -
3. Record then clear DTC(s).
Are DTCs P0741 and P0756 also set? Go to Step 2 Go to Step 5
Inspect circuit 524 from the I/P fuse block to the
2 engine fuse block for an open. -
Was condition found? Go to Step 3 Go to Step 4
Repair the short to ground in circuit 26/524.
3 - -
Was the condition found and corrected? Go to Step 29
Check circuit 528 for an open.
4 - -
Was the condition found and corrected? Go to Step 29
1. Select scan tool 1-2 Shift Solenoid.
2. Command solenoid ON and OFF three times.
5 3. Listen at transmission side cover. -
Does the solenoidclick when commandedON and
OFF? Go to Step 24 Go to Step 6
1. Ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTC(s) will set).
3. Using J 35616 Connector Test Adapter Kit,
connect a test light from terminal E to terminal A.
6 (See Connector View.) -
4. Ignition ON, engine OFF.
5. Command the 1-2 shift solenoid ON and OFF
three times.
Does the test light cycle ON andOFF as commanded? Go to Step 14 Go to Step 7

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DTC P0751 - 1-2 Shift Solenoid Performance (Cont’d)

Step Action Value(s) Yes No
7 Is the test light always ON? - Go to Step 8 Go to Step 11
1. Ignition OFF.
2. Disconnect the TCM connector (additional DTC(s)
8 will set). -
3. Ignition ON.
Is the test light ON? Go to Step 9 Go to Step 12
Check circuit 500 for a short to ground.
9 - -
Was the problem found? Go to Step 10
Repair the short to ground in circuit 500.
10 - -
Is the repair complete? Go to Step 29
11 Is the test light always OFF? - Go to Step 12 -
Check circuit 500 for an open.
12 -
Was the problem found and corrected? Go to Step 13 Go to Step 19
Repair the open in circuit 500.
13 - -
Is the repair complete? Go to Step 29
1. Ignition OFF.
2. Using J 35616 Connector Test Adapter Kit,
14 connect an ohmmeter from terminal E to
terminal A. (See Transmission Connector View.)
Does the ohmmeter display resistance as shown? 19 to 31 W Go to Step 17 Go to Step 15
15 Is the resistance greater than shown? § 250 W Go to Step 16 Go to Step 17
Check circuit 500 from the 20-way transmission
connector to the 1-2 SS Valve for an open or poor
16 connection at solenoid connector. - -
Was the problem found and corrected? Go to Step 29
Connect the ohmmeter from terminal A to a good
17 ground.
Is the resistance less than shown? ¦ 1000 W Go to Step 18 Go to Step 22
Check circuit 500 for a short to ground.
18 - -
was the problem found and corrected? Go to Step 29
Connect a test light from a good ground to
19 terminal A. -
Is the test light ON? Go to Step 20 Go to Step 23
Check circuit 500 for a short to battery power.
20 - -
Was the problem found? Go to Step 21
Repair the short to battery power in circuit 500.
21 - -
Is the repair complete? Go to Step 29
Replace the 1-2 Shift Solenoid valve.
22 Refer to Solenoid Replacement. - -
Is the replacement complete? Go to Step 29
Replace the TCM.
23 - -
Is the replacement complete? Go to Step 29
Has the transmission fluid checking procedure been Go to
24 performed? - Transmission
Go to Step 25 Fluid Check

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DTC P0751 - 1-2 Shift Solenoid Performance (Cont’d)

Step Action Value(s) Yes No
1. Use the scan tool to record current gear and gear
ratio.
2. Drive the vehicle in D to obtain 1-2, 2-3, and 3-4
25 shifts with TP greater than 8% and vehicle speed
greater than 8 km/h (5mph) for three seconds.
Is the current gear 2nd and the gear ratio within
range shown? 2.87-3.13 Go to Step 27 Go to Step 26
Is the current gear 1st and the gear ratio within
26
range shown? 1.54 -1.71 Go to Step 28 Go to Step 27
Is the commanded gear 3rd and the gear ratio within
27
range shown? 0.67-0.72 Go to Step 29 Go to Step 28
Is the commanded gear 4th and the gear ratio within Go to
28 range shown? Diagnostic
0.93-1.05 Go to Step 30 Aids
Repair the 1-2 shift circuit.
Check 1-2 shift circuit for the following:
D 1-2 shift Solenoid Valve mechanically stuck OFF.
29 D 1-2 Shift Solenoid Valve O-ring damage. - -
D 1-2 Shift valve stuck in released (downshift)
position.
Was the condition found and corrected? Go to Step 31
Repair the 1-2 shift circuit.
Check 1-2 shift circuit for the following:
D 1-2 Shift Valve mechanically stuck on.
30 D 1-2 Shift valve stuck in applied (upshift) position. - -
D 1-2 Shift valve stuck in released (downshift)
position.
Was the condition found and corrected? Go to Step 31
1. After the repair is complete, select scan tool
“Clear Info” function and road test the vehicle.
31 2. Review the “DTC Info”. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 128 4T40-E AUTOMATIC TRANSAXLE

B203A012

DIAGNOSTIC TROUBLE CODE (DTC) P0756

2-3 SHIFT SOLENOID PERFORMANCE

Circuit Description D No MAP is greater than 20 kPa.

The 2-3 Shift Solenoid Valve (2-3 SS Valve) is a normal- D Transmission fluid temperature is greater than
ly open valve that is used in conjunction with the * 10_C (14_F).
1-2 Shift Solenoid Valve (1-2 SS Valve) to allow four All the above conditions are true and any one of the
different shifting combinations (Refer to Shift Solenoid following conditions occur:
Chart). The 2-3 SS Valve blocks 2-3 signal fluid from ex-
D TCM commands 1st gear and 4th gear ratio between
hausting. 2-3 Signal fluid is routed to both the 1-2
0.67-0.72 is detected for 2 seconds.
and 2-3 shift valves. The solenoid is attached to the
valve body within the transmission. Voltage is supplied D TCM commands 2nd gear and 3rd gear ratio between
directly to the solenoid through the Transmission Control 0.93-1.05 is detected for 2 seconds.
Module (TCM). The TCM commands the solenoid ON or D TCM commands 3rd gear and 2nd gear ratio between
OFF by providing a ground path through circuit 500. 1.54-1.71 is detected for 3 seconds.
The Transmission Control Module (TCM) monitors the D TCM commands 4th gear and 1st gear ratio between
actual gear ratio, and compares the actual gear ratio 2.87-3.13 is detected for 4 seconds.
with the commanded gear ratio. DTC P0756 sets under
Action Taken When The DTC Is Set
four conditions:
D TCM will flash the Power Lamp.
D A stuck ON 2-3 SS Valve.
D Freeze shift adapts from being updated.
D A stuck OFF 2-3 SS Valve.
D TCM inhibits TCC engagement.
D A stuck ON 2-3 shift Valve.
D TCM commands maximum line pressure.
D A stuck OFF 2-3 shift Valve.
D Immediate landing to 2nd gear.
Conditions For Setting The DTC
D DTC P0756 will be stored in TCM memory.
D No TFP Val. Position Sw. DTC P1810.
Conditions For Clearing The DTC
D No TP Sensor DTC P1791.
D The TCM will turn the Power Lamp off after DTC
D No Input Speed Sensor DTC(s) P0716 or P0717.
P0756 passes condition test. This DTC passes when
D No Vehicle Speed Sensor DTC(s) P0722 or P0723. all conditions for setting the DTC are met and the
D Engine running. gear ratio matches the commanded gear for 3 con-
D Transmission is in D, 3, 2 or 1. secutive ignition cycles.
D Vehicle speed above 8 km/h (5 mph). D History DTC(s) can be cleared by using a scan tool.
D TP is greater than 8%.

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 129
Diagnostic Aids
D If the DTC cannot be reset after clearing the code,
check for possible fluid contamination, plugged or re-
stricted oil circuit.
D Inspect the wiring for poor electrical connections at
the TCM and at the transmission 20-way connector.
Look for possible bent, backed out, deformed or dam-
aged terminals. Check for weak terminal tension as
well. Also check for chafed wires that could short to
bare metal or other wiring. Inspect for broken wire in-
side the insulation.
D If diagnosing for a possible intermittent short or open A103A037

condition, move or massage the wiring harness while

observing test equipment for a change.
Shift Solenoid Status Chart

1-2 Shift 2-3 Shift

Gear
Solenoid Valve Solenoid Valve
1st ON OFF
2nd OFF OFF
3rd OFF ON
4th ON ON

A103A036

DTC P0756 - 2-3 Shift Solenoid Performance

Step Action Value(s) Yes No
1. Install the scan tool.
2. Ignition ON, engine OFF.
1 -
3. record then clear DTC(s).
Are DTCs P0751 and P0741 also set? Go to Step 2 Go to Step 5
Inspect circuit 524 from the I/P fuse block to the
2 engine fuse block for an open. -
Was the condition found? Go to Step 3 Go to Step 4
Repair the short to ground in circuit 524.
3 - -
Was the condition found and corrected? Go to Step 29
Check circuit 528 for an open.
4 - -
Was the condition found and corrected? Go to Step 29
1. Select scan tool 2-3 shift solenoid.
2. Command solenoid ON and OFF three times.
5 3. Listen at transmission side cover. -
Does the solenoid click when commanded ON and
OFF? Go to Step 24 Go to Step 6
1. Ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTC(s) will set).
3. Using J 35616 Connector Test Adapter Kit,
connect a test light from terminal E to terminal B.
6 (See Connector View.) -
4. Ignition ON, engine OFF.
5. Command the 2-3 Shift Solenoid ON and OFF
three times.
Does the test light cycle ON andOFF as commanded? Go to Step 14 Go to Step 7

DAEWOO J-100 BL2 / BL3

5A -- 130 4T40-E AUTOMATIC TRANSAXLE

DTC P0756 - 2-3 Shift Solenoid Performance (Cont’d)

Step Action Value(s) Yes No
7 Is the test light always ON? - Go to Step 8 Go to Step 11
1. Ignition OFF.
2. Disconnect the TCM connector (additional DTC(s)
8 will set). -
3. Ignition ON.
Is the test light ON? Go to Step 9 Go to Step 12
Check circuit 501 for a short to ground.
9 - -
Was the problem found? Go to Step 10
Repair short to ground in circuit 501.
10 - -
Is the repair complete? Go to Step 29
11 Is the test light always OFF? - Go to Step 12 -
Check circuit 501 for an open.
12 -
Was the problem found? Go to Step 13 Go to Step 19
Repair the open in circuit 501.
13 - -
Is the repair complete? Go to Step 29
1. Ignition OFF.
2. Using J 35616 Connector Test Adapter Kit,
14 connect an ohmmeter from terminal E to
terminal B. (See Transmission Connector View.)
Does the ohmmeter display resistance as shown? 19 to 31 W Go to Step 17 Go to Step 15
15 Is the resistance greater than shown? § 250 W Go to Step 16 Go to Step 17
Check circuit 501 from the transmission connector to
the solenoid for an open or poor connection at
16 connector. - -
Was the problem found and corrected? Go to Step 29
Connect the ohmmeter from terminal B to a good
17
ground is the resistance less than shown? ¦ 1000 W Go to Step 18 Go to Step 22
Check circuit 501 for a short to ground.
18 - -
Was the problem found and corrected? Go to Step 29
Connect a test light from a goodgroundto terminal B.
19 -
Is the test light ON? Go to Step 20 Go to Step 23
Check circuit 501 for a short to battery power.
20 - -
Was the problem found? Go to Step 21
Repair the short to battery power in circuit 501.
21 - -
Is the repair complete? Go to Step 29
Replace 2-3 Shift Solenoid Valve.
22 Refer to Solenoid Replacement. - -
Is the replacement complete? Go to Step 29
Replace the TCM.
23 - -
Is the replacement complete? Go to Step 29
Has the transmission fluid checking procedure been Go to
24 performed? - Transmission
Go to Step 25 Fluid Check

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 131

DTC P0756 - 2-3 Shift Solenoid Performance (Cont’d)

Step Action Value(s) Yes No
1. Use the scan tool to record current gear and gear
ratio.
2. Drive the vehicle in D to obtain a 2-3 shift with TP 1st:
25
greater than 8% and vehicle speed greater than 2.87 - 3.13 Go to
8 km/h (5 mph) for three seconds. 4th: Diagnostic
Are gear rations within given gear range? 0.61 - 0.72 Aids Go to Step 26
Does the engine labor upon start off, or is 3rd gear
26 -
indicated when 1st gear is commanded? Go to Step 28 Go to Step 27
Repair 2-3 Shift circuit.
Check 2-3 Shift SolenoidValve mechanically stuck off.
27 D Solenoid O-ring damage. - -
D 2-3 valve stuck in released position.
Was the condition found and corrected? Go to Step 29
Repair 2-3 shift circuit.
Check 2-3 shift circuit for the following:
28 D 2-3 Shift Solenoid Valve mechanically stuck off. - -
D 2-3 Shift valve stuck in applied position.
Was the condition found and corrected? Go to Step 29
1. After the repair is complete, select scan tool
“Clear Info” function and road test the vehicle.
29 2. Review the “DTC Info”. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 132 4T40-E AUTOMATIC TRANSAXLE

DIAGNOSTIC TROUBLE CODE (DTC) P1790

TCM CHECKSUM ERROR

Circuit Description D TCM inhibits TCC engagement.

A normal function of the transmission control module D Freeze shift adapts from being updated.
(TCM) programming is to perform an internal check that D TCM flashes the power lamp.
verifies the integrity of the RAM and ROM memory al-
D DTC P1790 will be stored in TCM memory.
locations. This function is called a checksum. When the
TCM runs this check and the memory allocations do not Conditions For Clearing The DTC
agree with the previous checksum, then DTC P1790 will D The TCM will turn the power lamp off after the TCM
set. checksum is correct for three consecutive ignition
Conditions For Setting The DTC cycles.
D Ignition ON. D History DTC(s) can be cleared by using a scan tool.
D TCM checksum is incorrect. Diagnostic Aids
Action Taken When The DTC Is Set D Flashing the TCM is not recommended. When DTC
P1790 sets, the TCM must be replaced.
D TCM commands maximum line pressure.
D TCM commands 2nd gear.

DTC P1790 - TCM Checksum Error

Step Action Value(s) Yes No
1. Install the scan tool.
2.Turn the ignition switch to the ON position.
3. Record then clear the DTC(s).
1 -
4. Turn the ignition OFF for 30 seconds.
5. Engine running Go to Diagnos-
Does DTC P1790 reset? Go to Step 2 tic Aids
Replace the TCM. Refer to TCM
2 Is the replacement complete? Verify repair and replacement
-
exit DTC Chart procedures

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 133

BLANK

DAEWOO J-100 BL2 / BL3

5A -- 134 4T40-E AUTOMATIC TRANSAXLE

B203A013

DIAGNOSTIC TROUBLE CODE (DTC) P1810

AUTOMATIC TRANSMISSION FLUID PRESSURE MANUAL VALVE
POSITION SWITCH (TFP VAL. POSITION SW.) MALFUNCTION

Circuit Description Conditions For Setting The DTC

The Automatic Transmission Fluid Pressure Manual This DTC will set under any one of the following three
Valve Position Switch (TFP Val. Position Sw.) consists of conditions:
six pressure switches. Five of the switches are normally
Condition 1
open and are used for determining gear range selection.
The sixth switch is a normally closed switch and is used D Engine running.
to detect TCC release fluid pressure. The TFP Val. Posi- D Gear range is illegal for five seconds.
tion Sw. also contains a Trans Fluid Temperature (TFT)
Condition 2
sensor. These components are combined into one unit
and mounted on the valve body. D No VSS DTC(s) P0722 or P0723.
The TCM provides battery voltage on each range signal. D Engine speed is in transition from 0 to more than
By grounding one or more of these switches with fluid 500 rpm.
pressure from the manual shift valve, the TCM detects D TFP Val. Position Sw. indicates D2, D4 or reverse at
what gear range has been selected. When the transmis- engine start-up.
sion electrical connector is disconnected and the ignition D All the above conditions are met for 2 seconds.
is on, the ground potential for three range signals from
the TCM will be removed and an illegal gear will be indi- Condition 3
cated. D Engine running.
When the TCM detects an invalid state of the TFP Val. D No TP DTC P1791.
Position Sw. then DTC P1810 sets. D No VSS DTC(s) P0722 or P0723.

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 135
D No Input Speed Sensor DTC(s) P0716 or P0717. D Inspect the wiring for poor electrical connections at
D MAP is 10-105 kPa. the TCM and at the transmission 20-way connector.
Look for possible bent, backed out, deformed or dam-
D No shift solenoid DTC(s) P0751 or P0756.
aged terminals. Check for weak terminal tension as
D Vehicle speed is equal to or greater than 8 km/h well. Also check for chafed wires that could short to
(5 mph). bare metal or other wiring. Inspect for broken wire in-
D TP is greater than 10%. side the insulation.
And any one of the following three conditions occur: D If diagnosing for a possible intermittent short or open
D TFP Val. Position Sw. indicates P (Park)/N (Neutral) condition, move or massage the wiring harness while
when gear ratio is less than 0.72 (4th gear) for 5 observing test equipment for a change.
seconds. Test Description
D TFP Val. Position Sw. indicates Reverse when ratio is The numbers below refer to the step numbers on the
greater than 2.23 or less than 2.02 for 5 seconds. diagnostic chart.
D TFP Val. Position Sw. indicates D, 3, 2, or 1 when ra- 4. This step tests the TCM’s ability to recognize an
tio indicates Reverse for 5 seconds. open circuit on signal ‘‘A’’, ‘‘B’’ and ‘‘C’’ ranges.
Action Taken When The DTC Sets
Gear Range Signal Range Signal Range Signal
D The TCM will flash the Power Lamp after two consec- Position A B c
utive trips with a failure reported.
Park ON OFF OFF
D Freeze shift adapts from being updated.
Reverse ON OFF ON
D TCM assumes D4 shift pattern.
Neutral ON OFF OFF
D Elevate line pressure.
Drive/OD ON ON OFF
D TCM inhibits TCC engagement.
D3/3rd OFF ON OFF
D DTC P1810 will be stored in TCM memory.
D2/2nd OFF ON ON
Conditions For Clearing the DTC
D1/Lo ON ON ON
Condition 1
Illegal OFF OFF OFF
D Engine running.
Illegal OFF OFF ON
D The TFP Val. Position Sw. does not detect an illegal
range for 5 seconds, three consecutive ignition cycles.
Condition 2
D When the following is true for three consecutive
ignition cycles.
- System voltage is 10-17 volts.
- No VSS DTC(s) P0722 or P0723.
- Vehicle speed less than 11 km/h (7 mph).
- TFP Val. Position Sw. indicates park or neutral for
3 seconds.
Condition 3
D After three consecutive ignition cycles when the A103A037

following is true:
- TFP Val. Position Sw. indicates P (Park) or N (Neu-
tral) when ratio is greater than 0.72 for 5 seconds.
- TFP Val. Position Sw. indicates Reverse when ra-
tio is between 2.02 and 2.23 for 5 seconds.
- TFP Val. Position Sw. indicates D or 3 or 2 or 1
when the ratio is less than 2.02 or greater than
2.23 for 5 seconds.
D History DTC(s) can be cleared by using a Scan Tool.
Diagnostic Aids
D A pressure regulator problem could possibly set
DTC P1810. A103A036

DAEWOO J-100 BL2 / BL3

5A -- 136 4T40-E AUTOMATIC TRANSAXLE

DTC P1810 - Automatic Transmission Fluid Pressure Manual Valve Position Switch
(TFP Val. Position Sw.) Malfunction
Step Action Value(s) Yes No
Has the transmission fluid checking procedure been Go to
1 performed? - Fluid Check
Go to Step 2 Procedures
Check the transmission shift linkage for proper
2 adjustment. -
Was the condition found and corrected? Go to Step 28 Go to Step 3
1. Install the scan tool.
2. Ignition ON, engine OFF.
3. Record then clear DTC(s).
4. Apply the parking brake.
5. Engine running. -
3 6. Apply the brakes and select each transmission
range (P, R, N, 1, 2, 3, D), while monitoring scan
tool.
Refer to Gear Position and Range Signal Chart.
Does each selected transmission range match scan Go to
tool and signal range chart? Diagnostic Aids Go to Step 4
1. Ignition OFF.
2. Disconnect the transmission 20-way connector
4 (additional DTC(s) will set).
3. Ignition ON, engine OFF. A B C
Is the TFP Switch display as shown? OFF/OFF/OFF Go to Step 11 Go to Step 5
5 Does the TFP Switch signal ‘‘A’’ display ON? - Go to Step 8 Go to Step 6
6 Does the TFP Switch signal ‘‘B’’ display ON? - Go to Step 9 Go to Step 7
7 Does the TFP Switch signal ‘‘C’’ display ON? - Go to Step 10 Go to Step 8
Check circuit 508 from the 20-way connector to
8 TCM for a short to ground. -
Was the condition found and corrected? Go to Step 28 Go to Step 27
Check circuit 510 from the 20-way connector to
9 TCM for a short ground. -
Was the condition found and corrected? Go to Step 28 Go to Step 27
Check circuit 509 from the 20-way connector to
10 TCM for a short to ground. -
Was the condition found and corrected? Go to Step 28 Go to Step 27
Note: While performing Steps 11, 12, and 13, if two
or more signal ranges display ON, those circuits will
be shorted together.
11 Using J 35616 Connector Test Adapter Kit, connect
a fused jumper wire from terminal N to a good
ground. (See Connector View.) A
Does the TFP Switch signal ‘‘A’’ display ON? ON Go to Step 12 Go to Step 13
Connect a fused jumper wire from terminal R to a
12 good ground. B
Does the TFP Switch signal ‘‘B’’ display ON? ON Go to Step 13 Go to Step 15
Connect a fused jumper wire from terminal P to a
13 good ground. C
Does the TFP Switch signal ‘‘C’’ display ON? ON Go to Step 17 Go to Step 16
Check circuit 508 from the 20-way connector to
14 TCM for an open. -
Was the condition found and corrected? Go to Step 28 Go to Step 27

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 137

DTC P1810 - Automatic Transmission Fluid Pressure Manual Valve Position Switch
(TFP Val. Position Sw.) Malfunction (Cont’d)
Step Action Value(s) Yes No
Check circuit 510 from the 20-way connector to
15 TCM for an open. -
Was the condition found and corrected? Go to Step 28 Go to Step 27
Check circuit 509 from the 20-way connector to
16 TCM for an open. -
Was the condition found and corrected? Go to Step 28 Go to Step 27
1. Ignition OFF.
2. Using J 35616 Connector Test Adapter Kit,
connect an ohmmeter from terminal N to a good
17 ground. (See Transmission Connector View.)
3. Observe the ohmmeter display.
Is the circuit resistance as shown? u 1000 W Go to Step 18 Go to Step 20
Connect an ohmmeter from terminal R to a good
18 ground. Observe the ohmmeter display.
Is the resistance as shown? u 1000 W Go to Step 19 Go to Step 21
Connect an ohmmeter from terminal P to a good
19 ground. Observe the ohmmeter display.
Is the resistance as shown? u 1000 W Go to Step 23 Go to Step 22
Check circuit 508 of the transmission harness for a
20 short to ground. -
Was the condition found and corrected? Go to Step 28 Go to Step 26
Check circuit 510 of the transmission harness for a
21 short to ground. -
Was the condition found and corrected? Go to Step 28 Go to Step 26
Check circuit 509 of the transmission harness for a
22 short to ground. -
Was the condition found and corrected? Go to Step 28 Go to Step 26
Check circuit 508 from the transmission 20-way
23 connector to TFP Val. Position Sw. for an open. -
Was the condition found and corrected? Go to Step 28 Go to Step 26
Check circuit 510 from the transmission 20-way
24 connector to TFP Val. Position Sw. for an open. -
Was the condition found and corrected? Go to Step 28 Go to Step 26
Check circuit 509 from the transmission 20-way
25 connector to TFP Val. Position Sw. for an open. -
Was the condition found and corrected? Go to Step 28 Go to Step 26
Replace the TFP Val. Position Sw.
Refer to Automatic Transmission Fluid Pressure
26 Manual Valve Position Switch (TFP Val. Position Sw.) - -
Replacement.
Is the repair complete? Go to Step 28
Replace the TCM.
27 - -
Is the replacement complete? Go to Step 28
1. After the repair is complete, select scan tool
“Clear Info” function and road test the vehicle.
28 2. Review the “DTC Info”. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 138 4T40-E AUTOMATIC TRANSAXLE

A103A313

DIAGNOSTIC TROUBLE CODE (DTC) P1811

MAXIMUM ADAPT AND LONG SHIFT

Circuit Description Conditions For Clearing The DTC

The transmission line pressure is modified by the TCM D After each ignition cycle without the fault condition
through the Pressure Control Solenoid Valve (PC Sol. present.
Valve) to control the gear shift execution time and shift D To cancel DTC fail actions, the fault must no longer
consistency. The TCM monitors various inputs and exist and the ignition must be cycled off for five
modifies the shift execution and timing by applying a seconds.
calculated duty cycle to the PC Sol. Valve, the TCM al-
D History DTC(s) can be cleared by using a Scan Tool.
ters the shifting based on driving habits, transmission
load and internal transmission condition. Diagnostic Aids
When the TCM detects long shifts that can not be D Question the owner for the possibility of vehicle over-
shortened by shift adapts during the same ignition cycle, loading, exceeding trailer towing limit, or towing in
then DTC P1811 sets. overdrive.
Conditions For Setting The DTC D If after several attempts to gain accurate shift times
and an adapt can be made, reset adapts and operate
D Shift time is greater than 1 second at maximum adapt vehicle to assure proper shifting.
for a total four times per ignition cycle.
Test Description
Action Taken When The DTC Sets
The numbers below refer to the step numbers on the
D TCM will NOT flash the Power Lamp. diagnostic chart.
D TCM will command maximum line pressure. 1. This step checks for possible low fluid level causing
D TCM will freeze shift adapts from being updated. delayed shift(s).
D DTC P1811 will be stored in TCM memory. 4. This step checks for possible low line pressure
causing delayed shift(s).
DAEWOO J-100 BL2 / BL3
 4T40-E AUTOMATIC TRANSAXLE 5A -- 139

DTC P1811 - Maximum Adapt and Long Shift

Step Action Value(s) Yes No
Has the transmission fluid checking procedure been Go to
1 performed? - Transmission
Go to Step 2 Fluid Check
1. Install the scan tool.
2. Ignition ON, engine OFF.
3. Record then clear DTC(s).
2 4. Drive the vehicle in D to obtain a 1-2, 2-3, and
3-4 upshifts.
5. With the scan tool, record 1-2, 2-3, 3-4 shift
times.
Did all shifts exceed time shown? u 1 second Go to Step 3 Go to Step 5
Perform the line pressure check. Go to
3 - Diagnostic Aids Go to Step 4
Was the line pressure within specifications?
Inspect the transmission for:
D Low fluid level caused by external leaks
D Clogged fuel filter
D Out-of-position fluid filter
D Internal fluid passage leaks
D Casting porosity or damage
D Damaged gasket or spacer plate
D Out-of-position gasket or spacer plate
D Contaminated PC Sol. Valve
D Damaged PC Sol. Valve - -
4
D Stuck PC Sol. Valve
D Stuck pressure regulator valve train
D Leaking pressure regulator valve train
D Stuck torque signal valve train
D Leaking torque signal valve train
D Leaking oil pump
D Damaged oil pump
D Inadequate oil pump suction
D Oil pump cavitation.
Was the condition found and corrected? Go to Step 10
5 Did 1-2 shift exceed time shown? u 1 second Go to Step 8 Go to Step 6
6 Did 2-3 shift exceed time shown? u 1 second Go to Step 9 Go to Step 7
7 Did 3-4 shift exceed time shown? u 1 second Go to Step 10 -

DAEWOO J-100 BL2 / BL3

5A -- 140 4T40-E AUTOMATIC TRANSAXLE

DTC P1811 - Maximum Adapt and Long Shift (Cont’d)

Step Action Value(s) Yes No
Inspect the 1-2 shift circuit for the following conditions:
D Leaking 1-2 accumulator piston seals
D Rolled 1-2 accumulator piston seals
D Cut 1-2 accumulator piston seals
D Leaking 2nd clutch piston seals
D Rolled 2nd clutch piston seals
D Cut 2nd clutch piston seals
D Burned 2nd clutch plates
D Damaged 2nd clutch plates
D Broken 2nd clutch springs
D Out-of-position 2nd clutch springs - -
8 D Damaged 2nd clutch piston
D Leaking driven sprocket support seals
D Damaged driven sprocket support seals
D Internal fluid passage leaks
D Casting porosity or damage
D Damaged gasket or spacer plate
D Out-of-position gasket or spacer plate
D Slipping forward clutch
D Cracked or damaged driven sprocket support
D Damaged sprag clutch (not holding)
D 2nd roller clutch damaged (not holding)
Was the condition found and corrected? Go to Step 11
Inspect the 2-3 shift circuit for the following conditions:
D Leaking 2-3 accumulator piston seals
D Rolled 2-3 accumulator piston seals
D Cut 2-3 accumulator piston seals
D Leaking direct clutch piston seals
D Rolled direct clutch piston seals
D Cut direct clutch piston seals
D Burned direct clutch plates
D Damaged direct clutch plates
D Broken direct clutch springs
9 D Out-of-position direct clutch springs - -
D Damaged direct clutch piston
D Leaking driven sprocket support seals
D Damaged driven sprocket support seals
D Damaged driven sprocket support
D Damaged (or not holding) sprag clutch
D Internal fluid passage leaks
D Casting porosity or damage
D Damaged gasket or spacer plate
D Out-of-position gasket or spacer plate
Was the condition found and corrected? Go to Step 11

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 141

DTC P1811 - Maximum Adapt and Long Shift (Cont’d)

Step Action Value(s) Yes No
Inspect the 3-4 shift circuit for the following conditions:
D Leaking 3-4 accumulator piston seals
D Rolled 3-4 accumulator piston seals
D Cut 3-4 accumulator piston seals
D Leaking intermediate/4th servo piston seals
D Rolled intermediate/4th servo piston seals
D Cut intermediate/4th servo piston seals
D Burned intermediate/4th band
D Out-of-position intermediate/4th band
D Damaged intermediate/4th band
D Slipping intermediate/4th band - -
10 D Internal fluid passage leaks
D Casting porosity or damage
D Damaged gasket or spacer plate
D Out-of-position gasket or spacer plate
D Slipping direct clutch
D Damaged intermediate/4th servo pin
D Seized intermediate/4th servo pin
D Damaged intermediate/4th servo piston
D Cracked intermediate/4th servo cover
D Leaking intermediate/4th servo cover
Was the condition found and corrected?
Go to Step 11
1. After the repair is complete, select scan tool
“Clear Info” function and road test the vehicle.
11 2. Review the “DTC Info”. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

DAEWOO J-100 BL2 / BL3

5A -- 142 4T40-E AUTOMATIC TRANSAXLE

A103A034

DIAGNOSTIC TROUBLE CODE (DTC) P1814

TORQUE CONVERTER OVERSTRESS

Circuit Description Conditions For Setting The DTC

This diagnostic checks for unusually high throttle angle D No TP DTC P1791.
and torque converter slip speed when the transmission D No VSS DTCs P0722 or P0723 are set.
is in a drive range. Sustained high torque converter
D No TFP Val. Position Sw. DTC P1810 is set.
slip speeds will generate excessive heat build-up in the
transmission fluid. Operating the vehicle under these D Transmission output speed is less than 1500 rpm.
conditions is unsafe and will damage the powertrain. D The transmission is in Drive or Reverse.
When the transmission fluid becomes overheated, it D The throttle angle is greater than 50%.
is less effective at providing cooling, lubrication, and
D The TCC slip speed is greater than 1500 rpm for
cleaning of the transmission components.
8 seconds.
When the TCM detects high throttle angle with high
torque converter slip then DTC P1814 will set.

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Action Taken When The DTC Is Set Test Description
D DTC P1814 will be stored in TCM memory. The numbers below refer to the step numbers on the
diagnostic chart.
Conditions For Clearing The DTC
1. This step inspects the fluid level and condition. If the
D When the TCC slip speed is less than 1450 rpm.
fluid condition is suspect, replace the fluid.
D History DTC(s) can be cleared by using a Scan Tool.
3. This step replaces the transmission fluid and filter,
Diagnostic Aids and flushes the transmission cooler.
A simultaneous acceleration and application of the
brakes may cause the DTC to occur.

DTC P1814 - Torque Converter Overstress

Step Action Value(s) Yes No
Inspect the transmission fluid level and condition. Go to
1 Is the insepction complete? - Fluid Checking
Go to Step 2 Procedures
Is the transmission fluid dark brown in color and
2
have a burnt odor? - Go to Step 3 Go to Step 4
Replace the transmission fluid and filter. Flush the
transmission cooler.
3 Refer to Changing Oil and Filter. - -
Refer to Transmission Cooler Flush.
Are the procedures complete? Go to Step 4
Advise the customer that overloading the vehicle,
exceeding the trailer-towing limit, towing in
4 Overdrive, or simultaneous acceleration and - -
application of the brakes can damage the Repair verified,
powertrain. exit DTC Chart

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B203A013

DIAGNOSTIC TROUBLE CODE (DTC) P1887

TCC RELEASE SWITCH CIRCUIT MALFUNCTION

Circuit Description D Transmission is in D4.

The Torque Converter Clutch (TCC) release switch is D TCC commanded On.
part of the Automatic Transmission Fluid Pressure D TCC slip speed is between -20 RPM and 20 RPM.
Manual Valve Position Switch (TFP Val. Position Sw.)
D TCC release switch is open.
that is mounted to the transmission valve body. The
switch is a normally closed switch. The purpose of the D All above conditions met for 8 seconds.
switch is to provide a signal to the Transmission Control
Action Taken When The DTC Is Set
Module (TCM) that the TCC is released. This is accom-
plishedby Torque Converter release fluid pressure acting D TCM will flash the Power Lamp after two consecutive
on the switch contact and opening the circuit. When the trips with a failure reported.
voltage is high on circuit 512, the TCM recognizes that D Freeze shift adapts from being updated.
the TCC is no longer engaged. D TCM inhibits TCC engagement.
When the TCM detects the TCC release switch is open D DTC P1887 will be stored in TCM memory.
indicating TCC is not applied and TCC slip speed indi-
cate the TCC is engaged, then DTC P1887 sets. Conditions For Clearing The DTC
D When the following is true for three consecutive
Conditions For Setting The DTC ignition cycles and:
D No Input Speed Sensor DTCs P0716 or P0717. - No Input Speed Sensor DTCs P0716 or P0717.
D No TCC stuck Off DTC P0741. - No TCC stuck Off DTC P0741.
D No TCC stuck On DTC P0742. - No TCC stuck On DTC P0742.
- Engine is running.
D Engine running.
- Transmission is in D4.
- TCC is commanded ON.

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 145
- TCC slip speed is between -20 RPM and 20 RPM. D If diagnosing for a possible intermittent short or open
- TCC Release Switch is closed. condition, move or massage the wiring harness while
- All above conditions are met for 8 seconds. observing test equipment for a change.
D History DTC(s) can be cleared by using a Scan Tool. Test Description
Diagnostic Aids The numbers below refer to the step numbers on the
D Inspect the wiring for poor electrical connections at diagnostic chart.
the TCM and at the transmission 20-way connector. 4. This Step tests the TCM’s ability to recognize an
Look for possible bent, backed out, deformed or dam- open circuit.
aged terminals. Check for weak terminal tension as 5. This Step tests the TCM’s ability to recognize a
well. Also check for chafed wires that could short to grounded circuit.
bare metal or other wiring. Inspect for broken wire in-
side the insulation.

DTC P1887 - TCC Release Switch Circuit Malfunction

Step Action Value(s) Yes No
1. Install the scan tool.
2. With the engine OFF, turn the ignition switch to
the ON position.
1
3. Record then clear DTC(s).
4. Select scan tool TCC Release Switch.
Is the TCC Release Switch status as shown? Closed Go to Step 2 Go to Step 4
Start the engine.
2
Is the TCC Release Switch status as shown? Open Go to Step 13 Go to Step 3
1. Ignition OFF.
2. Disconnect the transmission 20-way connector
(additional DTC(s) will set).
3
3. With the engine OFF, turn the ignition switch to
the ON position.
Is the TCC Release Switch status as shown? Open Go to Step 7 Go to Step 6
1. Install the J 39775 Jumper Harness to the engine
20-way connector.
2. Using the J 35616 Connector Test Adapter Kit,
4
connect a fused jumper from terminal U to a good
ground.
Is the TCC Release Switch status as shown? Closed Go to Step 7 Go to Step 5
Inspect circuit 512 for an open.
5 -
Was the condition found and corrected? Go to Step 14 Go to Step 12
Inspect circuit 512 for a short to ground.
6 -
Was the condition found and corrected? Go to Step 14 Go to Step 12
1. IDisconnect the J 39775 Jumper Harness from
the engine 20-way connector.
2. Install the J 39775 Jumper Harness to the
transmission 20-way connector.
7
3. Using the J 35616 Connector Test Adapter Kit,
connect an ohmmeter from terminal U to a good
ground.
Is the resistance less than the specified value? 50 W Go to Step 8 Go to Step 9
Start the engine.
8
Is the resistance greater than the specified value? 50 W Go to Step 9 Go to Step 10
Inspect circuit 512 of the internal wiring harness for
9 an open. -
Was the condition found and corrected? Go to Step 14 Go to Step 11

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DTC P1887 - TCC Release Switch Circuit Malfunction (Cont’d)

Step Action Value(s) Yes No
Inspect circuit 512 of the internal wiring harness for
10 a short to ground. -
Was the condition found and corrected? Go to Step 14 Go to Step 11
Replace the TFP Val. Position Sw.
Refer to Automatic Transmission Fluid Pressure - -
11
Manual Valve Position Switch Replacement.
Is the replacement complete? Go to Step 14
Replace the TCM.
12 Refer to TCM Replacement. - -
Is the replacement complete? Go to Step 14
Inspect for the following conditions:
D Leaking torque converter O-ring seal (41).
Refer to Case and Associated Parts in Automatic
Transmission Component Location.
D Cut torque converter O-ring seal (41).
D Debris or flash blocking the channel plate (27).
Refer to Case and Associated Parts in Automatic
Transmission Component Location at the TCC
release exhaust passage (48), refer to Channel
Plate Passages in Automatic Transmission
Component Location.
D Leaking oil pump bearing and seal assembly
(200) seal. Refer to Oil Pump Assembly in
Automatic Transmission Component Location.
D Cut oil pump bearing and seal assembly (200)
seal.
D Oil pump bearing and seal assembly (200)
installed backward.
13 D Misalignedvalve body-to-spacer plate gasket (22).
Refer to Case andAssociatedParts in Automatic - -
Transmission Component Location.
D Misaligned spacer plate-to-channel plate gasket
(24).
D Channel plate (27) turbine shaft sleeve installed
backward or with no press fit.
D Valve body spacer plate (23), refer to Case and
Associated Parts in Automatic Transmission
Component Location or release exhaust orifice
(46), refer to Channel Plate Passages in
Automatic Transmission Component Location
blocked by debris, valve body-to-spacer plate
gasket (22) or spacer plate-to-channel plate
gasket (24).
D Cut turbine shaft-to-sprocket seal (33). Refer to
Case and Associated Parts in Automatic
Transmission Component Location.
D Missing turbine shaft-to-sprocket seal (33).
Was the condition found and corrected? Go to Step 14
1. After the repair is complete, select scan tool
“Clear Info” function and road test the vehicle.
14 2. Review the “DTC Info”. -
Has the last test failed or is the current DTC Begin Repair verified,
displayed? Diagnosis again exit DTC Chart

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 147

MAINTENANCE AND
REPAIR
ON-VEHICLE SERVICE
TRANSAXLE FLUID LEVEL
CHECKING PROCEDURE
1. Start the engine and allow the engine to idle for
approximately 5 minutes, or, if possible, drive the ve-
hicle for a few miles to warm the transaxle fluid.
Check the fluid level when the transaxle is above
40_C (104_F).
2. Park the vehicle on a hoist, inspection pit, or similar
raised-level surface. The vehicle must be level to ob-
tain a correct fluid level measurement.
3. Place a fluid container below the fluid level plug.

4. Depress the brake pedal and move the shift lever

through the gear ranges, pausing a few seconds in
each range. Return the shift lever to the PARK
position. (Left-hand drive shown, right-hand drive
similar.)

A103A344

Caution: Do not remove the fluid level plug if the

transaxle fluid is hot. This may cause injury if the
fluid drains from the plug hole.
5. Remove the fluid level plug. Because the transaxle
operates correctly over a range of fluid levels, fluid
may or may not drain out of the plug hole when the
plug is removed.
6. If fluid does not drain through the plug hole after
adding a total of 1.5 liters, then the transaxle was ei-
ther underfilled or the transaxle is leaking fluid. In-
spect the transaxle for fluid leaks. Fix any leaks
before setting the transaxle fluid level.
7. Install the fluid level plug.
Tighten
Tighten the fluid level plug to 12 NSm (106 lb-in).
8. When the fluid level checking procedure is com-
pleted, wipe any fluid from the transaxle case with a
rag or shop towel. Also, check that the fluid fill cap
A103A048
and the vent tube are properly installed.

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CHANGING THE FLUID

1. Disconnect the negative battery cable.
2. Remove the transaxle fluid filter and the filter seal.
Refer to “Fluid Filter and Seal” in this section.
3. Flush the oil cooler. Refer to “Oil Cooler Flushing” in
this section.
4. Install the transaxle fluid filter and the filter seal. Refer
to “Fluid Filter and Seal” in this section.
5. Add transaxle fluid. Refer to “Transaxle Fluid Level
Checking Procedure” in this section.
6. Connect the negative battery cable.

REPAIRING FLUID LEAKS

Locating Leaks
General Method
1. Verify that the leak is transaxle fluid.
2. Thoroughly clean the suspected leak area.
3. Operate the vehicle for about 15 miles or until the
transaxle reaches normal operating temperature,
88_C (190_F).
4. Park the vehicle over clean paper or cardboard.
5. Shut the engine off and look for fluid spots on the pa-
per.
6. Make the necessary repairs to correct the leak.

A103A342

Powder Method
1. Thoroughly clean the suspected leak area.
2. Apply an aerosol-type powder (foot powder) to the
suspected leak area.
3. Operate the vehicle for about 15 miles or until the
transaxle reaches normal operating temperature,
88_C (190_F).
4. Shut the engine off.
5. Inspect the suspected leak area and trace the leak
path through the powder to find the source of the
leak.
6. Make the necessary repairs.

A103A341

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 149
Repairing the Fluid Leak
The following are potential causes for fluid leaks. Check
these and repair as necessary.
D Fasteners are not tightened to specifications.
D Fastener threads and tapped holes are dirty or
corroded.
D Gaskets, seals or sleeves are misaligned, damaged,
or worn.
D The seal bore or the gasket surface is damaged,
warped, or scratched.
D The manual shaft is nicked or damaged.
D There is a loose or worn bearing causing excess seal
or sleeve wear.
D Case or component porosity.
D The fluid level is too high.
D There is a plugged vent or a damaged vent tube.
D There is water or coolant in the fluid.
D Fluid drain back holes are plugged.

CASE POROSITY REPAIR

Caution: Epoxy adhesive may cause skin irritations
and eye damage. Read and follow all information on
the container label as provided by the manufacturer.
1. Thoroughly clean the area to be repaired with a
cleaning solvent. Air dry the area.
2. Using instructions from the manufacturer, mix a suffi-
cient amount of epoxy to make the repair.
3. While the transaxle case is still hot, apply the epoxy.
You can use a clean, dry soldering acid brush to clean
the area and also apply the epoxy cement. Make
certain that the area to be repaired is fully covered.
4. Allow the epoxy cement to cure for 3 hours before
starting the engine.
5. Repeat the fluid leak diagnosis procedures. Refer to
“Fluid Leak Diagnosis and Repair” in this section.
A103A343

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FLUID LEVEL SET AFTER SERVICE

1. Add transaxle fluid through the fill cap hole prior to ad-
justing the fluid level. The amount of fluid to add
should be based on the type of service done. If the
bottom pan was removed, add 7 liters (7.4 quarts). If
a new torque converter was installed, add 2.5 liters
(2.6 quarts). If a complete overhaul was done, refill
the system with 10 liters (10.6 quarts). Use DEX-
RONr-III transaxle fluid only.
2. Check the transaxle fluid level. Refer to “Transaxle
Fluid Level Checking Procedure” in this section.
3. Add additional fluid through the fill cap hole in 0.5 liter
increments until the fluid comes out through the plug
hole.
4. Allow the fluid to finish draining out through the plug
hole, then install the fluid level plug.
Tighten
Tighten the fluid level plug to 12 NSm (106 lb-in).
5. When the fluid level setting procedure is completed,
wipe any fluid from the transaxle case with a rag or
shop towel. Also, check that the fluid fill cap and the
vent tube are properly installed.

OIL COOLER FLUSHING

1. Disconnect both cooler lines from the transaxle. Re-
fer to “Oil Cooler Hoses” in this section.
2. Place a hose over the end of the cooler inlet line (from
the top of the cooler) and insert the hose into an
empty container.
3. Flush clean transaxle fluid through the return line
(from the bottom of the cooler) using an oil suction
gun until clean transaxle fluid comes out of the hose.
This will back flush the cooler.
Important: If transmission fluid does not come out of
the hose from the radiator, the cooler tubes within the
radiator are damaged. The radiator should be repaired
or replaced.
4. Remove the hose from the inlet cooler line and place
it on the return line.
A103A057

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 151
5. Flush clean transaxle fluid through the inlet line until
clean transaxle fluid comes out of the return line. Re-
move the remaining transaxle fluid with compressed
air. Flush with new transaxle fluid.
6. Reconnect the oil cooler lines to the transaxle. Refer
to “Oil Cooler Hoses” in this section.

SHIFT CONTROL LEVER

(Left-Hand Drive Shown, Right-Hand Drive
Similar)
Removal Procedure
1. Remove the right and the left front lower trim panels,
the shift control panel, and the floor console. Refer to
Section 9G, Interior Trim.
2. Remove the selector position switch.
3. Remove the nuts from the shift control cable mount-
ing bracket at the front of the shift control assembly.

B103A301

4. Loosen the nut on the shift control cable adjuster

pinch bolt.

B103A308

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5. Slide the shift control cable out of the shift control
cable adjuster and remove the pinch bolt.

B103A302

6. Remove the bolt from the bottom of the shift control

lever.

B103A303

7. Tilt the shift control lever to the left side and remove
the spring-loaded detent ball.

B103A304

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 153
8. Remove the shift control lever by pressing the lock
release button while pivoting the bottom of the shift
control lever toward the front of the vehicle.

B103A305

9. Slide the detent spring out of the shift control lever.

B103A306

10. Remove the bolts holding the shift control assembly

to the floor panel.
11. Remove the shift control assembly.

B103A307

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5A -- 154 4T40-E AUTOMATIC TRANSAXLE

Installation Procedure
1. Install the shift control assembly in the floor panel
with the bolts.
Tighten
Tighten the shift control assembly bolts to NSm (lb-ft).

B103A307

2. Install the detent spring into the shift control lever.

B103A306

3. Install the shift control lever by pressing the lock re-

lease button while pivoting the bottom of the shift con-
trol lever toward the rear of the vehicle.

B103A305

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 155
4. Tilt the shift control lever to the left and install the
spring-loaded detent ball.

B103A304

5. Install the bolt in the bottom of the shift control lever.

Tighten
Tighten the shift control lever bolt to NSm (lb-ft).

B103A303

6. Insert the shift control cable adjuster pinch bolt into

the shift control assembly and slide the shift control
cable into the shift control cable adjuster.

B103A302

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5A -- 156 4T40-E AUTOMATIC TRANSAXLE
7. Attach the shift control cable mounting bracket to
the shift control assembly with the nuts.
Tighten
Tighten the shift control cable mounting bracket nuts
to 6 NSm (53 lb-in).

B103A301

8. Install the nut on the shift control cable adjuster

pinch bolt. Do not tighten.
9. Perform a control cable adjustment. Refer to
“Control Cable Adjustment” in this section.
Tighten
Tighten the shift control cable adjuster pinch bolt nut
to 8 NSm (71 lb-in).

B103A308

Notice: Make sure the slot in the selector position

switch is all the way forward and the shift control lever
is in the P position. Failure to do so may damage to
the selector position switch and produce a false gear in-
dication.
10. Install the selector position switch on the shift
control assembly.
11. Install the floor console, the shift control panel, and
the right and the left front lower trim panels. Refer to
Section 9G, Interior Trim.

B103A300

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 157

SHIFT CONTROL CABLE

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the shift control cable from the selector le-
ver.
3. Disconnect the shift control cable from the bracket.

A103A049

4. Remove the right and the left front lower trim panels,
the shift control panel and the floor console. Refer to
Section 9G, Interior Trim.
5. Loosen the pinch bolt nut on the shift control lever.

B103A001

6. Remove the shift control cable from the shift control

assembly by holding one nut while loosening the oth-
er one.

B103A002

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7. Pull the shift control cable through the fire wall of the
vehicle, bringing the rubber grommet with it.

B103A005

Installation Procedure
1. Push the shift control cable through the fire wall of the
vehicle and install the rubber grommet.

B103A005

2. Install the brass housing and the nut onto the oppo-
site end of the shift control cable.

B103A006

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 159
3. Install the shift control cable into the shift control as-
sembly.
4. Install the shift control attachment nut onto the shift
control assembly.
Tighten
Tighten the shift control cable attachment nut to
6 NSm (53 lb-in).

B103A002

5. Insert the shift control cable into the connecting slot

on the shift control lever and secure it with the pinch
bolt and nut.
Tighten
Tighten the shift control cable adjustment pinch bolt
nut to 8 NSm (71 lb-in).

B103A001

6. Install the shift control cable into the engine compart-

ment bracket and secure with the clip.

A103A049

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7. Install the shift control cable onto the selector lever
and secure with the clip.
8. Perform a control cable adjustment. Refer to
“Control Cable Adjustment” in this section.
9. Install the floor console, the shift control panel and
the right and the left lower trim panels. Refer to
Section 9G, Interior Trim.
10. Connect the negative battery cable.

A303A001

CONTROL CABLE ADJUSTMENT

1. Disconnect the negative battery cable.
2. Move the shift lever to the PARK position.
3. Make sure the range selector lever on the transaxle is
in the PARK position.

A303A002

4. Remove the right and the left front lower trim panels,
the shift control panel, and the floor console. Refer to
Section 9G, Interior Trim.
5. Loosen the shift control cable adjustment pinch bolt.
6. Pull the shifter control cable until it is tight.
Tighten
Tighten the shift control cable adjustment pinch bolt
to 8 NSm (71 lb-in).
7. Install the floor console, the shift control panel, and
the right and the left lower trim panels. Refer to
Section 9G, Interior Trim.
8. Connect the negative battery cable.

B103A001

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 161

NEUTRAL START SWITCH

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the neutral start switch electrical connec-
tor.
3. Disconnect the shift control cable and the retaining
clip.

A303A001

4. Remove the shift lever nut and the shift lever.

5. Remove the neutral start switch.

A303A003

Installation Procedure
1. Install the neutral start switch.
2. Install the shift lever and the shift lever nut.

A303A003

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5A -- 162 4T40-E AUTOMATIC TRANSAXLE
3. Connect the shift control cable and the retaining clip.
4. Connect the neutral start switch electrical connector.
5. Connect the negative battery cable.

A303A001

AUTOMATIC TRANSMISSION
OUTPUT SPEED SENSOR (A/T OSS)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the A/T OSS electrical connector.
3. Remove the A/T OSS stud (61).
Notice: Be sure to pull the A/T OSS straight out of the
transaxle case in order to prevent damage to the case
bore.
4. Pull the A/T OSS (62) straight out of the transaxle
case.
5. Remove the O-ring (63) from the A/T OSS (62).

A103A311

Installation Procedure
1. Inspect the A/T OSS for damage. Clean and dry the
A/T OSS. Install the O-ring (63) on the A/T OSS (62).
2. Install the A/T OSS (62) in the transaxle case.
3. Install the A/T OSS stud (61).
Tighten
Tighten the A/T OSS stud (61) to 12 NSm (106 lb-in).
4. Connect the A/T OSS electrical connector.
5. Connect the negative battery cable.

A103A311

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 163

PAN, GASKET, AND FILTER

Removal Procedure
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Place a fluid container below the oil pan.
4. Remove the transaxle oil pan bolts (81) and the pan
(88).
5. Remove the transaxle oil pan gasket (87). The gasket
is reusable.

A103A310

6. Remove the transaxle filter (85) and the neck seal

(84).

A103A305

Installation Procedure
1. Install a new transaxle filter neck seal (84) and a
transaxle filter (85).

A103A305

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2. Inspect the gasket (87) and the pan (88) for cracks,
dents, or cuts. Install the transaxle pan (88) and the
gasket (87).
3. Install the transaxle pan bolts (81).
Tighten
Tighten the transaxle pan bolts (81) to 12 NSm
(106 lb-in).
4. Lower the vehicle.
5. Refill the transaxle fluid. Refer to “Transaxle Fluid
Level Checking Procedure” in this section.
6. Connect the negative battery cable.

A103A310

REVERSE/LOW SERVO ASSEMBLY

Removal Procedure
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the transaxle pan, gasket, and filter. Refer to
‘‘Pan, Gasket and Filter’’ in this section.
4. Remove the servo cover bolts (25) and the servo cov-
er (73).
5. Remove the piston assembly and the return spring
(66).

A103A307

Installation Procedure
1. Install the return spring (66) and the piston assembly.
2. Install the servo cover (73) and the servo cover bolts
(25).
Tighten
Tighten the servo cover bolts (25) to 12 NSm (106 lb-in).
3. Install the transaxle filter, gasket, and pan. Refer to
‘‘Pan, Gasket and Filter’’ in this section.
4. Lower the vehicle.
5. Refill the transaxle fluid. Refer to “Transaxle Fluid
Level Checking Procedure” in this section.
6. Connect the negative battery cable.

A103A307

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 165

2ND/4TH SERVO ASSEMBLY

Removal Procedure
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the transaxle pan, gasket, and filter. Refer to
‘‘Pan, Gasket, and Filter’’ in this section.
4. Remove the servo cover bolts (25) and the servo cov-
er (80).
5. Remove the piston assembly and the return spring
(75).

A103A308

Installation Procedure
1. Install the servo return spring (75), the piston assem-
bly, the servo cover (80), and servo cover bolts (25).
Tighten
Tighten the servo cover bolts (25) to 12 NSm (106 lb-in).
2. Install the transaxle filter, gasket, and pan. Refer to
‘‘Pan, Gasket, and Filter’’ in this section.
3. Lower the vehicle.
4. Refill the transaxle fluid. Refer to “Transaxle Fluid
Level Checking Procedure” in this section.
5. Connect the negative battery cable.

A103A308

CASE SIDE COVER PAN AND

GASKETS
Tools Required
J-28467-B Engine Support Fixture
Removal Procedure
1. Disconnect the negative battery cable.
2. Install the engine support fixture J-28467-B. (Left-
hand drive shown, right-hand drive similar.)

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3. Raise and suitably support the vehicle.
4. Remove the front exhaust pipe. Refer to Section
1G, Engine Exhaust.
5. Remove the left wheel. Refer to Section 2E, Tires
and Wheels.
6. Remove the left drive axle. Refer to Section 3A, Au-
tomatic Transaxle Drive Axle.
7. Remove the battery and the battery tray. Refer to
Section 1E, Engine Electrical.
8. Remove the left transaxle mount. Refer to “Trans-
axle Mount” in this section.
9. Lower the engine until the side cover is accessible.
10. Remove the shifter linkage and the neutral start
switch. Refer to “Neutral Start Switch” in this sec-
tion.
11. Remove the side cover bolts (3 and 4), the side cov-
A103A083 er (1), and the gaskets (6 and 7).

Installation Procedure
1. Install the side cover (1), the gaskets (6 and 7), and
the side cover bolts (3 and 4).
Tighten
Tighten the side cover bolts (3 and 4) to 20 NSm
(15 lb-ft).

A103A083

2. Install the shifter linkage and the neutral start

switch. Refer to “Neutral Start Switch” in this
section.
3. Raise the engine.
4. Install the left transaxle mount. Refer to “Transaxle
Mount” in this section.
5. Install the battery and the battery tray. Refer to
Section 1E, Engine Electrical.
6. Install the left drive axle. Refer to Section 3A, Auto-
matic Transaxle Drive Axle.
7. Install the left wheel. Refer to Section 2E, Tires and
Wheels.
8. Install the front exhaust pipe. Refer to Section 1G,
Engine Exhaust.
9. Lower the vehicle.
10. Remove the engine support fixture J-28467-B. (Left-
hand drive shown, right-hand drive similar.)
B103A032 11. Connect the negative battery cable.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 167

1-2 SHIFT SOLENOID

Removal Procedure
1. Remove the transaxle side cover. Refer to “Case
Side Cover and Gaskets” in this section.
2. Disconnect the electrical connection from the 1-2 shift
solenoid (305).
Important: Use a small screwdriver in order to remove
the retainer clips. Be careful not to score the valve body
when removing the retainer clips.
3. Remove the solenoid retainer clip (304) from the
valve body.
4. Remove the 1-2 shift solenoid (305).

A103A219

Installation Procedure
1. Install the 1-2 shift solenoid (305) into the valve body.
2. Install the retainer clip (304) into the valve body.
3. Connect the electrical connection to the solenoid
(305).
4. Install the transaxle side cover. Refer to “Case Side
Cover and Gaskets” in this section.

A103A219

2-3 SHIFT SOLENOID

Removal Procedure
1. Remove the transaxle side cover. Refer to “Case
Side Cover and Gaskets” in this section.
2. Disconnect the electrical connection from the 2-3 shift
solenoid (305).
Notice: Use a small screwdriver in order to remove the
retainer clips. Be careful not to score the valve body
when removing the retainer clips.
3. Remove the solenoid retainer clip (304) from the
valve body.
4. Remove the 2-3 shift solenoid (305).

A103A218

DAEWOO J-100 BL2 / BL3

5A -- 168 4T40-E AUTOMATIC TRANSAXLE

Installation Procedure
1. Install the 2-3 shift solenoid (305) into the valve body.
2. Install the retainer clip (304) into the valve body.
3. Connect the electrical connection to the 2-3 shift
solenoid (305).
4. Install the transaxle side cover. Refer to “Case Side
Cover and Gaskets” in this section.

A103A218

PRESSURE CONTROL SOLENOID

Removal Procedure
1. Remove the transaxle side cover. Refer to “Case
Side Cover and Gaskets” in this section.
2. Disconnect the electrical connection from the pres-
sure control solenoid (PCS) (312).
Notice: Use a small screwdriver in order to remove the
retainer clips. Be careful not to score the valve body
when removing the retainer clips.
3. Remove the solenoid retainer clip (304) from the
valve body.
4. Remove the pressure control solenoid (312).

A103A217

Installation Procedure
1. Install the pressure control solenoid (312) into the
valve body.
2. Install the retainer clip (304) into the valve body.
3. Connect the electrical connection to the pressure
control solenoid (312).
4. Install the transaxle side cover. Refer to “Case Side
Cover and Gaskets” in this section.

A103A217

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 169

TCC SOLENOID
Removal Procedure
1. Remove the transaxle side cover. Refer to “Case
Side Cover and Gaskets” in this section.
2. Disconnect the electrical connection from the TCC
solenoid (335).
Notice: Use a small screwdriver in order to remove the
retainer clips. Be careful not to score the valve body
when removing the retainer clips.
3. Remove the solenoid retainer clip (304) from the
valve body.
4. Remove the TCC solenoid (335).

A103A220

Installation Procedure
1. Install the TCC solenoid (335) into the valve body.
2. Install the retainer clip (304) into the valve body.
3. Connect the electrical connection to the solenoid
(335).
4. Install the transaxle side cover. Refer to “Case Side
Cover and Gaskets” in this section.

A103A220

DRIVE AXLE OIL SEAL

Tools Required
J-41102 Axle Seal Installer
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the drive axles. Refer to Section 3A, Auto-
matic Transaxle Drive Axle.
Notice: Be careful not to damage the bore of the
transaxle case.
3. Remove the transaxle drive seal using a screwdriver.
If necessary, crush the seal first with the screwdriver
in order to loosen the seal from the case.

A103A312

DAEWOO J-100 BL2 / BL3

5A -- 170 4T40-E AUTOMATIC TRANSAXLE

Installation Procedure
1. Install the transaxle drive seal (2) using the axle seal
installer J-41102.
2. Install the drive axles. Refer to Section 3A, Automatic
Transaxle Drive Axle.
3. Connect the negative battery cable.

A103A238

OIL COOLER PIPES

Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the transaxle oil pan and the filter. Refer to
“Pan, Gasket, and Filter” in this section.
3. Remove the oil pipe bolts (81) and the pipes (83) from
the transaxle case (51).

A103A309

Installation Procedure
1. Install the oil pipes (83) and the oil pipe bolts (81).
Tighten
Tighten the oil pipe bolts (81) to 12 NSm (106 lb-in).
2. Install the transaxle oil pan and filter. Refer to “Pan,
Gasket, and Filter” in this section.
3. Connect the negative battery cable.

A103A309

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 171

OIL COOLER HOSES AND PIPE

Removal Procedure
Important: Place a drip pan under the hoses to catch
the fluid that will run out of the lines.
1. Loosen the hose clamps and disconnect the hoses
from the transaxle.

A103A057

2. Remove the oil cooler pipe bracket bolt and discon-

nect the oil cooler pipe from the upper end of the ra-
diator. Remove the oil cooler pipe and hose from the
vehicle.

B203A015

3. Loosen the hose clamp at the lower end of the radia-

tor and remove the cooler hose from the vehicle.

B203A016

DAEWOO J-100 BL2 / BL3

5A -- 172 4T40-E AUTOMATIC TRANSAXLE

Installation Procedure
1. Install the cooler hose onto the lower end of the
radiator and tighten the hose clamp.

B203A016

2. Install the cooler pipe and hose onto the upper end of
the radiator.
Tighten
Tighten the oil cooler pipe bolt to 22 NSm (16 lb-ft).
Tighten the oil cooler pipe bracket bolt to 25 NSm
(18 lb-ft).

B203A015

3. Install the hoses onto the transaxle.

4. Tighten the transaxle hose clamps.
5. Refill the transaxle fluid. Refer to “Transaxle Fluid
Checking Procedure” in this section.

A103A057

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 173

TRANSAXLE MOUNT
Tools Required
J-28467-B Engine Support Fixture
Removal Procedure
1. Install the engine support fixture J-28467-B. (Left-
hand drive shown, right-hand drive similar.)

B103A032

2. Remove the coolant surge tank.

B103A030

3. Remove the transaxle mount upper attachment nut.

4. Raise and suitably support the vehicle.
5. Remove the left front wheel. Refer to Section 2E,
Tires and Wheels.

B203A017

DAEWOO J-100 BL2 / BL3

5A -- 174 4T40-E AUTOMATIC TRANSAXLE
6. Remove the bolts from the transaxle mount.
7. Remove the transaxle mount from the vehicle.

B203A018

Installation Procedure
1. Install the transaxle mount and the transaxle mount
bolts.
Tighten
Tighten the transaxle mount bolts to 81 NSm (60 lb-
ft).

B203A018

2. Install the transaxle mount upper attachment nut.

Tighten
Tighten the transaxle mount upper attachment nut
to 169 NSm (125 lb-ft).

B203A017

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 175
3. Install the left front wheel. Refer to Section 2E, Tires
and Wheels.
4. Lower the vehicle.
5. Install the coolant surge tank.
6. Remove the engine support fixture J-28467-B. (Left-
hand drive shown, right-hand drive similar.)
7. Refill the transaxle fluid. Refer to “Transaxle Fluid
Level Checking Procedure” in this section.

B103A032

TRANSAXLE BRACKET
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the pivot bolt.

B203A019

3. Remove the bolts and the transaxle mounting bracket

from the vehicle.

B203A020

DAEWOO J-100 BL2 / BL3

5A -- 176 4T40-E AUTOMATIC TRANSAXLE

Installation Procedure
1. Install the transaxle mounting bracket and the
transaxle mounting bracket bolts.
Tighten
Tighten the transaxle mounting bracket bolts to
61 NSm (45 lb-ft).

B203A020

2. Install the pivot bolt.

Tighten
Tighten the pivot bolt to 58 NSm (43 lb-ft).
3. Lower the vehicle.

B203A019

TRANSAXLE ASSEMBLY
Tools Required
J-28467-B Engine Support Fixture
Removal Procedure
1. Disconnect the negative battery cable.
Important: Be sure to have a pan ready to catch any
transaxle fluid that might come out.
2. Disconnect the transaxle cooler lines from the
transaxle.

A103A057

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 177
3. Disconnect the transaxle wiring harness.

A103A063

4. Disconnect the neutral start switch electrical connec-

tor.
5. Disconnect the shift cable from the shift lever and the
shift cable mounting bracket.

A103A049

6. Disconnect the automatic transmission output speed

sensor (A/T OSS) electrical connector.

A103A072

DAEWOO J-100 BL2 / BL3

5A -- 178 4T40-E AUTOMATIC TRANSAXLE
7. Remove the front exhaust pipe. Refer to Section
1G, Engine Exhaust.
8. Remove the drive axles. Refer to Section 3A, Auto-
matic Transaxle Drive Axle.
9. Remove the flywheel inspection shield.
10. Remove the flywheel bolts.

A103A303

11. Install the engine support fixture J-28467-B. (Left-

hand drive shown, right-hand drive similar.)

B103A032

12. Install the transaxle support jack.

A103A066

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 179
13. Remove the bell housing bolts.
14. Remove the transaxle brace mounting bolts.

A103A067

15. Disconnect the transaxle mount bolts.

B203A018

16. Remove the transaxle mounting bracket bolts.

17. Remove the transaxle from the vehicle.

B203A021

DAEWOO J-100 BL2 / BL3

5A -- 180 4T40-E AUTOMATIC TRANSAXLE

Installation Procedure
1. Install the transaxle into the vehicle.
2. Install the transaxle mounting bracket bolts.
Tighten
Tighten the transaxle mounting bracket bolts to
61 NSm (45 lb-ft).

B203A021

3. Connect the transaxle mount bolts.

Tighten
Tighten the transaxle mount bolts to 81 NSm (60 lb-ft).

B203A018

4. Connect the transaxle brace mounting bolts.

Tighten
Tighten the transaxle brace mounting bolts to 75 NSm
(55 lb-ft).

A103A067

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 181
5. Install the bell housing bolts.
Tighten
Tighten the bell housing bolts to 75 NSm (55 lb-ft).
6. Install the flywheel bolts.
Tighten
Tighten the flywheel bolts to 65 NSm (48 lb-ft).
7. Install the flywheel inspection shield.

A103A303

8. Remove the transaxle support jack.

9. Remove the engine support fixture J-28467-B. (Left-
hand drive shown, right-hand drive similar.)

B103A032

10. Install the drive axles. Refer to Section 3A, Automat-

ic Transaxle Drive Axle.
11. Install the front exhaust pipe. Refer to Section 1G,
Engine Exhaust.
12. Connect the A/T OSS electrical connector.

A103A072

DAEWOO J-100 BL2 / BL3

5A -- 182 4T40-E AUTOMATIC TRANSAXLE
13. Connect the shift cable to the shift lever and the shift
cable mounting bracket.

A303A001

14. Connect the neutral start switch electrical connec-

tor.
15. Connect the transaxle wiring harness.

A103A063

16. Connect the transaxle cooler lines to the transaxle

and install the hose clamps.
17. Add transaxle fluid. Refer to “Transaxle Fluid Level
Checking Procedure” in this section.
18. Connect the negative battery cable.

A103A057

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 183

TRANSAXLE BRACE
Tools Required
J-28467-B Engine Support Fixture
Removal Procedure
1. Install the engine support fixture J-28467-B. (Left-
hand drive shown, right-hand drive similar.)
2. Raise and suitably support the vehicle.
3. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.

B103A032

4. Remove the transaxle brace mounting bolts.

5. Remove the engine mounting bolts.
6. Remove the transaxle brace.

A103A072

Installation Procedure
1. Install the transaxle brace.
2. Loosely install the transaxle brace mounting bolts.
3. Install the engine mounting bolts.
Tighten
Tighten the transaxle brace mounting bolts to 75 NSm
(55 lb-ft).
Tighten the engine mounting bolts to 75 NSm (55 lb-
ft).

A103A072

DAEWOO J-100 BL2 / BL3

5A -- 184 4T40-E AUTOMATIC TRANSAXLE
4. Remove the engine support fixture J-28467-B. (Left-
hand drive shown, right-hand drive similar.)
5. Install the right front wheel. Refer to Section 2E, Tires
and Wheels.
6. Lower the vehicle.

B103A032

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 185

UNIT REPAIR
TORQUE CONVERTER REMOVAL
1. Remove the torque converter assembly (55).
2. Remove the turbine shaft O-ring (41) from the end of
the turbine shaft.

A103A074

TRANSAXLE HOLDING FIXTURE

ASSEMBLY
Tools Required
J 41230 Transmission Support Fixture
J 3289-20 Support Fixture
Caution: To reduce the possibility of personal inju-
ry or transmission damage, make sure, when doing
the next step, that all of the bolts for the support fix-
ture are installed as shown, and that the bolts are
tightened to 11 NSm (98 lb-in).
1. Install the J 41230 transmission support fixture onto
the transmission.
2. Torque the support fixture bolts to 11 NSm (8 lb-ft.)
3. Install the transmission and the support fixture onto
the J 3289-20 fixture base.
A103A075
4. Position the transmission with the side cover facing
down.
5. Insert the pin into the J 3289-20 fixture base in order
to lock the unit into place.

DAEWOO J-100 BL2 / BL3

5A -- 186 4T40-E AUTOMATIC TRANSAXLE

STUB SHAFT REMOVAL

Tools Required
J 6125-1B Slide Hammer
J 38868 Shaft Remover
Important: Handle the stub shaft carefully. The stub
shaft sleeve is reusable if the sleeve is not damaged or
removed from the stub shaft. Damage to the stub shaft
sleeve will result in a transmission fluid leak.
1. Remove and discard the snap ring (57) from the end
of the stub shaft (68). The stub shaft snap ring is not
reusable.
2. Attach the J 6125-1B to the J 38868. Install the
J 38868 into the snap ring groove on the stub shaft
(58). Tighten the J 38868 securely to the stub shaft.
3. Pull lightly on the shaft and rotate it until the stub shaft
A103A076 snap ring at the differential seats in the taper on the
differential side gear.
Important: Confirm that the stub shaft snap ring (57 is
properly seated in the differential side gear. If not, dam-
age may occur to the transmission when you attempt to
remove the stub shaft (58).
4. Pull the stub shaft (58) out with the slide hammer im-
pact.

AUTOMATIC TRANSMISSION
OUTPUT SPEED SENSOR (A/T OSS)
REMOVAL
1. Rotate the transmission so that the case side cover is
facing upward in order to drain the transmission fluid
through the stub shaft end of the transmission.
2. Rotate the transmission with the oil pan facing up-
ward.
3. Remove the output speed sensor stud (61).
4. Remove the output speed sensor assembly (62). Pull
the speed sensor assembly straight out from the
transmission case in order to prevent damage to the
case bore.
5. Remove the O-ring (63).

A103A077

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 187

OIL PAN AND GASKET REMOVAL

1. Remove the twelve oil pan bolts (81).
2. Remove the oil pan (88). The magnet can remain in
the oil pan.
3. Remove the oil pan gasket (87). The oil pan gasket is
reusable.

A103A078

OIL FILTER/SEAL, OIL LEVEL

CONTROL VALVE REMOVAL
1. Remove the transmission filter assembly (85).
Important: You may use a small screwdriver in order
to pry the seal from case. Be careful not to score or
damage the case with the screwdriver.
2. Remove the filter neck seal (84) from the transmis-
sion case. The filter neck seal (84) is not reusable and
should be discarded.
3. Remove the oil level control valve (86).

A103A079

OIL FEED PIPES REMOVAL

Important: The feed pipe seal rings (82) are glued into
place and should remain with the feed pipe assembly
(83). The feed pipe seal rings are reusable.
Remove the four oil feed pipe bolts (81) and remove the
oil feed pipe assembly (83).

A103A080

DAEWOO J-100 BL2 / BL3

5A -- 188 4T40-E AUTOMATIC TRANSAXLE

INTER 4TH SERVO REMOVAL

1. Remove the three servo cover bolts (25).
2. Remove the servo cover (intermediate/fourth) (80)
assembly.
3. Remove the servo return spring (75).

A103A081

LOW/REVERSE SERVO REMOVAL

1. Remove the three servo cover bolts (25).
2. Remove the servo cover (Lo/Reverse) (73).
3. Remove the servo return spring (66).

A103A082

CASE SIDE COVER REMOVAL

1. Rotate the transmission so that the side cover faces
upward.
2. Remove the 11 side cover bolts (3) or studs (4) (model
dependant).
3. Remove the transmission side cover (1).
4. Remove the two side cover gaskets (5 and 6) and the
side cover to driven support thrust washer (7), if they
did not remain with the side cover.

A103A083

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 189

OIL PUMP AND OIL PUMP SHAFT

REMOVAL
1. Remove the eight bolts from the oil pump (8, 9 and
12).
2. Remove the oil pump assembly (10).
3. Remove the oil pump shaft (19).

A103A084

WIRE HARNESS DISCONNECT

1. Disconnect the wiring harness connectors from the
pressure control solenoid (312).
2. Disconnect the wiring harness connectors from the
1-2 and 2-3 shift solenoids (305).
3. Disconnect the wiring harness connectors from the
pressure switch assembly (13).
4. Disconnect the wiring harness connectors from the
TCC solenoid (335).

A103A085

PRESSURE SWITCH ASSEMBLY

REMOVAL
1. Remove the six bolts from the pressure switch as-
sembly (8, 12 and 16).
2. Remove the pressure switch assembly (PSA) (13)
from the control valve body assembly (18). The seven
pressure switch O-rings are reusable and should re-
main with the pressure switch assembly.

A103A086

DAEWOO J-100 BL2 / BL3

5A -- 190 4T40-E AUTOMATIC TRANSAXLE

CONTROL VALVE BODY ASSEMBLY

AND GASKET REMOVAL
1. Remove the remaining twelve bolts (8, 12 and 16)
from the control valve body assembly (18).
2. Remove the control valve body assembly (18).
3. Remove and discard the valve body to spacer plate
gasket (22).

A103A087

SPACER PLATE AND GASKET

REMOVAL
1. Remove the two spacer plate support bolts (20).
2. Remove the spacer plate support (21).
3. Remove the spacer plate (23) with the spacer plate
filter (17) attached.
4. Remove and discard the spacer plate to channel
plate gasket (24).

A103A088

CHECKBALL REMOVAL
Important: Do not use a magnet in order to remove the
checkballs. The magnet may magnetize the checkballs,
and the checkballs may attract metallic particles.
Remove the seven checkballs (26) in the channel plate.

A103A089

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 191

MANUAL VALVE CLIP REMOVAL

1. Disconnect the manual valve clip (801) from the
manual valve.
2. Disconnect the manual valve link (802) from the
manual valve.

A103A090

CHANNEL PLATE AND GASKET

REMOVAL
1. Remove the ten channel plate bolts (8 and 25).
2. Remove the channel plate assembly (27). Keep the
following components with the channel plate:
D The drive sprocket to channel plate thrust washer
(34).
D The three accumulator pistons (29)
D The manual valve (800)
D The detent lever spring (804) and bolt (805)
3. Remove and discard the channel plate to case gasket
(28).

A103A091

ACCUMULATOR SPRING REMOVAL

Remove the three accumulator springs (31 and 32) from
the case.

A103A092

DAEWOO J-100 BL2 / BL3

5A -- 192 4T40-E AUTOMATIC TRANSAXLE

OUTPUT SHAFT SLEEVE REMOVAL

Tools Required
J 41227 Output Shaft Sleeve Puller
Important: Do not remove the output shaft (94) in the
same manner as the stub shaft. In order to remove the
output shaft (94), you must completely disassemble the
transmission. Removing the output shaft (94) at this
time will damage other transmission components.
1. Insert the legs of J 41227 under the output shaft
sleeve (56).
2. Tighten the center bolt of the J 41227 down in order
to pull the output shaft sleeve (56) off the output shaft
(94).
3. Remove and discard the output shaft sleeve (56).
Use the J 41227. The output shaft sleeve is not reus-
A103A093
able.

DRIVE, DRIVEN SPROCKETS, DRIVE

LINK REMOVAL
Important: When removing the drive link assembly (36)
note which direction the chain faces. You must later
install the chain in the same direction in order to prevent
excessive noise.
1. Remove, as an entire unit, the drive sprocket (37), the
turbine shaft (39), the driven sprocket (81) and the
drive link assembly (36).
2. If the drive sprocket to drive sprocket support thrust
washer (38) has not remained with the drive sprocket
assembly (37 and 39), remove the drive sprocket to
drive sprocket support thrust washer (38). The driven
sprocket to driven sprocket support thrust washer
(92) should remain with the driven sprocket support
assembly (95).
A103A094

INPUT SPEED SENSOR REMOVAL

1. Remove the wiring harness connector at the input
speed sensor (46).
2. Remove the input speed sensor bolt (15) and the in-
put speed sensor (46).
3. Remove the wire retainer slip bolt (15) and retainer
clip.

A103A095

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 193

WIRING HARNESS REMOVAL

Tools Required
J 41101 Pass-Through Connector Remover
1. Push the J 41101 onto the pass-through connector
from the outside of the transmission case in order to
compress the pass-through connector’s retaining
tabs.
2. With the retaining tabs compressed, use a screwdriv-
er in order to remove the pass-through connector
through the inside of the transmission case.
3. Remove the wiring harness (11).

A103A096

DRIVEN SPROCKET SUPPORT

ASSEMBLY REMOVAL
1. Remove the driven sprocket to driven sprocket
support thrust washer (92).
2. Remove the driven sprocket support assembly (95).

A103A097

2ND CLUTCH PLATES REMOVAL

1. Remove the 2nd clutch wave plate (96).
2. Remove the three 2nd clutch steel plates (97).
3. Remove the three 2nd clutch fiber plates (98).
4. Remove the backing plate (99).

A103A098

DAEWOO J-100 BL2 / BL3

5A -- 194 4T40-E AUTOMATIC TRANSAXLE

REVERSE INPUT CLUTCH HOUSING

REMOVAL
1. Remove the driven sprocket support to reverse clutch
housing thrust washer (101).
2. Remove the reverse input clutch housing and the 2nd
roller clutch assembly (102).

A103A099

INTERMEDIATE 4TH BAND REMOVAL

Remove the intermediate 4th band (100).

A103A100

DIRECT/COAST CLUTCH AND

REACTION GEAR SET REMOVAL
Important: Keep the bearing assembly (103) and the
selective thrust washer (104) on top of the direct/coast
clutch and reaction carrier assembly (105).
Remove the direct/coast clutch and reaction carrier as-
sembly (105).

A103A101

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 195

INPUT CARRIER AND REACTION

GEAR ASSEMBLY REMOVAL
1. Remove the input carrier and reaction internal gear
assembly (106). A bearing assembly is permanently
inside the input carrier.
2. Remove the input carrier to forward clutch hub thrust
bearing (107). The input carrier to forward clutch hub
thrust bearing may have remained with the input car-
rier.

A103A102

INPUT INTERNAL GEAR, FORWARD

CLUTCH HUB REMOVAL
1. Remove the input internal gear and forward clutch
hub assembly (108).
2. If the forward clutch hub to race thrust washer (109)
did not remain with the forward clutch hub, remove
the forward clutch hub to race thrust washer (109).

A103A103

FORWARD CLUTCH AND

LOW/REVERSE BAND REMOVAL
1. Remove the forward clutch assembly (110).

A103A104

DAEWOO J-100 BL2 / BL3

5A -- 196 4T40-E AUTOMATIC TRANSAXLE
2. Remove the low/reverse band (111).

A103A105

FORWARD CLUTCH SUPPORT, LOW

ROLLER CLUTCH REMOVAL
Tools Required
J 28585 Snap Ring Screwdriver
Important: The snap ring opening must be at the bot-
tom of the transmission case. If the snap ring opening is
out of position, inspect the transmission case for dam-
age.
1. Remove the forward clutch support snap ring (112)
from the transmission case. Use the J 28585.

A103A106

Important: You may need to depress the parking pawl

in order to remove the forward clutch support.
2. Remove the forward clutch support and the low roller
clutch assembly (114). Keep the forward clutch hous-
ing to the forward clutch support thrust bearing (113)
with the forward clutch support assembly (114).

A103A107

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 197

OUTPUT SHAFT AND FINAL DRIVE

ASSEMBLY REMOVAL
1. Remove, as one unit, the output shaft (94), the final
drive assembly (116), and the final drive sun gear
(115).
2. If the differential carrier to case thrust bearing (117)
did not remain with the final drive assembly (116), re-
move the differential carrier to case thrust bearing
(117).

A103A108

FINAL DRIVE INTERNAL GEAR

REMOVAL
Important: The fretting ring (119) is in the case ring
groove. Do not remove the fretting ring unless it appears
damaged.
Remove the final drive internal gear (118).

A103A109

MANUAL SHAFT, DETENT LEVER,

PARK LOCK REMOVAL
1. Remove the manual shaft to transmission case pin
(803).
Important: The parking lock actuator assembly (807)
remains attached to the manual shaft and detent lever
until the assembly is removed.
2. Remove the manual shaft and detent lever assembly
(806) by pushing the manual shaft into the transmis-
sion case (51). The parking lock actuator assembly
(807) remains attached to the detent lever until you
remove the manual shaft and detent lever assembly.
Important: Do not damage the case bore during remov-
al of the manual shaft seal (809).
3. Remove the manual shaft seal (809) from the case
(51).
A103A110

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5A -- 198 4T40-E AUTOMATIC TRANSAXLE

TRANSAXLE COOLER LINE SEAL

REMOVAL
Tools Required
J 41239-2 Cooler Line Seal Removal Tool
1. Use a hammer in order to wedge the J 41239-2 into
the transmission cooler line seal (49) on the outside
of the case bore.
2. Remove the transmission cooler line seal by prying
the transmission cooler line seal out of the case. If
necessary strike the J 41239-2 with a hammer.

A103A111

TORQUE CONVERTER SEAL

REMOVAL
Tools Required
J 41103 Torque Converter Seal Remover
1. Insert the three J 41103 puller legs under the torque
converter seal (54).
2. Insert the J 41103 support body over the stator shaft
(43).
3. Insert the J 41103 puller bridge over the J 41103 sup-
port body. Connect the J 41103 puller legs into the
slots on the J 41103 bridge.
Important: The puller legs will damage the torque con-
verter seal (54). Discard the torque converter seal (54)
after removal.
4. Tighten the forcing screw on the J 41103 puller bridge
until the J 41103 puller legs remove the torque con-
A103A112 verter seal (54).

DRIVE SPROCKET SUPPORT

REMOVAL
1. Remove the six bolts (53) from the drive sprocket
support (43).
2. Remove the drive sprocket support (43) from the
case (51).

A103A113

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 199

RIGHT HAND AXLE SEAL REMOVAL

Important: Be careful not to damage the case bore with
the screwdriver.
Use a screwdriver in order to remove the right hand axle
seal (2) from the transmission case (51). If necessary,
crush the right hand axle seal first with the screwdriver in
order to loosen the seal from the case.

A103A114

CASE INSPECTION
Notice: Use Transjelt J 36850 or equivalent during as-
sembly in order to retain checkballs or to lubricate com-
ponents. Greases other than the recommended
assembly lube will change the transmission fluid charac-
teristics and will cause undesirable shift conditions or fil-
ter clogging.
Important: After cleaning the transmission case, allow
the case to air dry. Do not use cloth or paper towels in
order to dry the transmission case or any other trans-
mission components. Lint from the towels can cause
component failure.
1. Thoroughly clean the transmission case and all the
case threads with solvent.
2. Inspect the case exterior and the external bores for
cracks, sharp edges, porosity and excessive bushing
A103A115 wear.
3. Inspect the case interior for damage at the snap ring
grooves, case lugs and band anchor pin.
4. Inspect all the gasket surfaces for surface damage
and in order to ensure surface flatness.
5. Inspect the corresponding gasket for proper impres-
sions in order to ensure surface flatness.
6. Inspect the bolt holes and fasteners for thread dam-
age. If necessary, repair or replace any bolt holes or
fasteners.
7. Air check the oil passages. For identification of the
oil passages, refer to the transmission diagnosis
section.

DAEWOO J-100 BL2 / BL3

5A -- 200 4T40-E AUTOMATIC TRANSAXLE

ACTUATOR GUIDE REPLACEMENT

Important: Do not remove the actuator guide unless the
actuator guide appears damaged.
1. Remove the actuator guide roll pin (810) from the
case.
2. Remove the actuator guide (812) and O-ring seal
(811) assembly from the case (51). For easiest re-
moval, tap the actuator guide (812) into the case (51).
3. Install a new O-ring seal (811) on the actuator guide
(812).
4. Install the actuator guide (812) and O-ring assembly
(811) into the transmission case (51).
5. Install the actuator guide roll pin (810) into the case
(51) in order to secure the actuator guide (812).

A103A116

DRIVE SPROCKET SUPPORT

INSTALLATION
1. Inspect the drive sprocket support (43) for damage to
the stator shaft splines, the journals, the bushings,
and the roller bearing.
2. Inspect the converter seal drain holes for blockage.

A103A117

3. Install the drive sprocket support (43) into the bell

housing of the transmission case.
4. Install the six drive sprocket support bolts (53) into
the drive sprocket support (43).
5. Hand start the bolts and tighten the bolts to 12 NSm
(9 lb-ft).

A103A113

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 201

TORQUE CONVERTER SEAL

INSTALLATION
Tools Required
J 28540 Torque Converter Seal Installer
Install a new torque converter seal (54). Use the
J 28540.

A103A118

TRANSAXLE COOLER LINE SEALS

INSTALLATION
Tools Required
J 41239-1 Cooler Line Seal Installer
1. Place a new cooler line seal (49) in the case bore.
2. Install the J 41239-1 on the transmission case (51) at
the cooler line bracket bolt hole.
3. Press the new cooler line seal (49) in by tightening
the seal pressing bolt on the J 41239-1 until the seal
bottoms out in the case bore.
4. Repeat steps 1-3 for the second cooler line seal (49).

A103A119

MANUAL SHAFT, DETENT LEVER,

PARK LOCK INSTALLATION
Tools Required
J 41229 Manual Shaft to Case Pin Installer
1. Install a new manual shaft seal (809) into the case
(51). Use a 13 mm socket.

A103A120

DAEWOO J-100 BL2 / BL3

5A -- 202 4T40-E AUTOMATIC TRANSAXLE
2. With the manual valve to detent lever link (802) and
the parking lock actuator assembly (807) attached,
install the manual shaft and detent lever assembly
(806) into the case.
3. Ensure that the parking lock actuator rod is correctly
positioned into the actuator guide.

A103A110

Important: Install the manual shaft pin at the correct

height in order to properly secure the manual shaft. The
J 41229 provides the correct installation height. If you
install the pin too deep, the case boss might crack.
4. Install the manual shaft pin (803) into the case. Use
the J 41229.

A103A121

FINAL DRIVE ASSEMBLY

DISASSEMBLE
1. Remove the differential pinion shaft retaining pin
(704). Use a pin punch.

A103A122

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 203
Important: If the pinion gears are removed, place the
final drive carrier into a clean transmission oil pan in or-
der to prevent losing the needle bearings.
2. Remove the differential pinion shaft (703).

A103A123

Important: The snap ring (57) is not reusable. Discard

the snap ring (57).
3. Remove the snap ring (57) from the end of the output
shaft (94).
4. Remove the output shaft (94) from the differential car-
rier (702).
5. Remove the final drive sun gear (115).

A103A124

6. Remove the differential pinion gears (707) and the

thrust washers (706).
7. Remove the differential side gears (709) and the
thrust washers (708).

A103A125

DAEWOO J-100 BL2 / BL3

5A -- 204 4T40-E AUTOMATIC TRANSAXLE
8. Remove the final drive carrier spiral retaining ring
(701).

A103A126

Important: When removing the pinion gears, note the

orientation. You must install the pinion gears in the same
direction in which you removed the pinion gears. If you
install the pinion gear upside down. the change in set
wear patterns will cause a noise condition.
9. Remove the four planet pinion pins (714).
10. Remove the four pinion gears (711).
11. Remove the pinion thrust washers (710).
12. Remove the needle roller bearings (712).
13. Remove the needle bearing spacers (713).
14. Remove the final drive sun gear to carrier thrust
bearing (700).

A103A127

15. Inspect the needle roller bearings (712), the pinion

thrust washers (710), the pinion gears (711), and the
planet pinion pins (714) for excessive wear. Polish-
ing is a normal condition for the pinion pins and the
needle bearings.
16. Inspect the pinion shaft (714) for spalling or for wear.
17. Inspect the pinion thrust washers (710) for wear and
for cracks.
18. Clean and dry the final drive carrier and the final
drive components.

A103A128

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 205

FINAL DRIVE ASSEMBLY ASSEMBLE

Tools Required
J 36850 Transjelt
Important: You must assemble the spacer between the
two rows of needle bearings. In order to aid in the as-
sembly of the needle bearings, place the spacer and the
pinion gear onto the planet pinion gear pin (714).
1. Install the pinion gear needle bearing spacer (713)
onto the planet pinion gear (711).

A103A129

2. Place a thrust washer (710) on the bottom of the plan-

et pinion (711) in order to retain the bottom row
of needle bearings.
3. Use J 36850 or equivalent in order to aid in the as-
sembly and in order to keep the needle roller
bearings (712) in the race.
4. Install the needle roller bearings (712) one at a time
into the planet pinion (711).

A103A130

5. Install the sun gear to final drive carrier thrust bearing

(700) onto the final drive carrier (116). Retain the
thrust bearing with J 36850 or equivalent.
Important: Assemble the pinion gears (711) in the same
direction that you removed the pinion gears in order to
prevent noise due to changing the gear wear pattern.
6. Assemble the pinion gear thrust washers (710) and
the planet pinion gears into the final drive carrier
(116).
7. Install the planet pinion gear pins (714) into the final
drive carrier (116) in order to retain the planet pinion
gears (711).

A103A127

DAEWOO J-100 BL2 / BL3

5A -- 206 4T40-E AUTOMATIC TRANSAXLE
8. Install the final drive carrier spiral retaining ring (701)
in order to retain the planet pinion gear pins.

A103A126

9. Assemble the thrust washers (708) onto the differ-

ential side gears (709).
10. Install the differential side gears into the final drive
carrier (116).
11. Assemble the thrust washers (706) onto the pinion
gears (707). Retain the thrust washers with J 36850
or equivalent.
12. With the thrust washers (706) attached, install the
pinion gears (707) into the final drive carrier (116).
13. Rotate the pinion gears (707) into position, and
install the pinion shaft (703) through the final drive
carrier (116) and through the pinion gears (707).
14. Position the pinion shaft (703) in order to allow
installation of the retaining pin.
15. Install the retaining pin (704) through the final drive
carrier (116) and through the pinion shaft (703) in or-
der to retain the pinion shaft (703).
A103A125

FINAL DRIVE PINION END PLAY

CHECK
1. Inspect the end play with a feeler gauge for proper
clearance. Proper clearance is 24-62 mm (0.009-
0.024 inch).
2. If the clearance is out of specification on the low side,
repair the differential assembly as necessary.
3. If the clearance is out of specification on the high
side, replace the differential assembly.

A103A131

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 207

FRETTING RING, FINAL DRIVE

INTERNAL GEAR INSTALL
1. If the fretting ring 9119) has been removed, install
the fretting ring (119) into the small groove in the
transmission case (51).
2. Install the final drive internal gear (118) into the
transmission case (51).

A103A109

FINAL DRIVE AND DIFFERENTIAL

ASSEMBLY INSTALL
Tools Required
J 36850 Transjelt
1. Install the final drive carrier to case thrust bearing
(117) onto the final drive carrier. Retain the bearing
with J 36850.
2. Install the complete final drive carrier assembly (116)
into the transmission case (51).
Important: Install the sun gear with the grooved side up
(flat side down).
3. Install the final drive sun gear (115) into the final drive
carrier (116).

A103A132

FORWARD CLUTCH SUPPORT,

ROLLER CLUTCH DISASSEMBLE
1. Remove the roller clutch assembly (652) from the for-
ward clutch support (656) by turning the roller clutch
assembly (652) clockwise and gently lifting upward.
2. Remove the thrust bearing (113) from the forward
clutch support (656).

A103A133

DAEWOO J-100 BL2 / BL3

5A -- 208 4T40-E AUTOMATIC TRANSAXLE
3. Remove the final drive sun gear shaft snap ring
(660).
4. Remove the parking pawl gear (659).
5. Remove the forward clutch support to parking pawl
gear thrust bearing (658).
6. Remove the forward clutch support (656) from the
final drive sun gear shaft (651).

A103A134

Important: The parking pawl pin has a pressed fit into

the forward clutch support. The parking pawl pin is not
serviceable. Do not remove the parking pawl pin.
7. Remove and discard the two seals (654) from the
forward clutch support (656).

A103A135

8. Inspect the snap ring for overextension (660).

9. Inspect the seal grooves for damage (656).
10. Inspect for signs of excessive bearing and bushing
wear.
11. Inspect the splines and the parking gear teeth for
cracks or excessive wear.
12. Inspect the fluid feed holes for the proper opening.
13. Inspect all other components for excessive wear or
damage.
14. Clean and dry all of the components.

A103A136

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 209

FORWARD CLUTCH SUPPORT, LOW

ROLLER CLUTCH ASSEMBLE
1. Assemble two new seals (654) on the forward clutch
support (656).

A103A135

2. Assemble the forward clutch support (656) onto the

final drive sun gear shaft (651).
3. Assemble the roller bearing (658) onto the forward
clutch support (656).
4. Assemble the parking pawl gear (659) onto the final
drive sun gear shaft (651) with the raised inner boss
facing up, so that the parking pawl properly engages
the teeth on the parking pawl gear.
Important: The space between the parking pawl gear
(659) and the snap ring (660) is approximately 3 mm
(0.12 inch).
5. Assemble the snap ring (660) to the final drive sun
gear shaft (651) in order to retain the parking pawl
gear (659).

A103A134

6. Assemble the lo roller clutch assembly (652) onto the

forward clutch support (656). The larger tabs on the
cage must face down into the forward clutch support
(656). Rotate the cage slightly counterclockwise in or-
der to lock the tabs into the grooves in the forward
clutch support (656).
7. Assemble the thrust bearing (113) onto the forward
clutch support (656).

A103A133

DAEWOO J-100 BL2 / BL3

5A -- 210 4T40-E AUTOMATIC TRANSAXLE

FORWARD CLUTCH SUPPORT, LOW

ROLLER CLUTCH INSTALL
1. Install the forward clutch support and lo roller clutch
assembly (114) into the transmission case (51). Com-
press the parking pawl spring, and line up the parking
pawl with the parking pawl gear.

A103A137

Important: When installing the forward clutch support

snap ring (112), the snap ring opening must be toward
the bottom of the transmission case and facing the bot-
tom pan.
2. Install the forward clutch support snap ring (112) into
the transmission case with the chamfer side up. Use
a screwdriver in order to set the snap ring into place.

A103A106

FORWARD CLUTCH DISASSEMBLE

Tools Required
J 23327 Return Spring Compressor
J 41097-2 Inner Seal Remover-Disc
J 25031-A Puller/Inner Seal Remover
1. Remove the snap ring (600) from the housing assem-
bly (609).
2. Remove the backing plate (601).
3.Remove the seven fiber plates (602).
4. Remove the seven steel plates (603).
5. Remove the wave plate (604).

A103A138

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 211
Important: In order to prevent damage to the spring as-
sembly (606), only compress the return spring assembly
(606) enough so that you can remove the snap ring
(605).
6. Compress the forward clutch return spring assem-
bly. Use the J 23327.
7. Remove the return spring snap ring (605).
8. Remove the J 23327.

A103A139

9. Remove the forward clutch return spring assembly

(606).
10. Remove the forward clutch piston and seal assem-
bly (607).

A103A140

11. Inspect the forward clutch inner seal assembly (608)

for damage.
12. If the seal is damaged, place the J 41097-2 on the
inner hub of the clutch housing.
13. Remove the seal. Use the J 25031-A.

A103A141

DAEWOO J-100 BL2 / BL3

5A -- 212 4T40-E AUTOMATIC TRANSAXLE
14. Inspect the housing, the plates, the bushings, the
splines, the band apply surface, the roller clutch
race, and the spring assembly.
15. Inspect fluid feed holes for proper openings.
16. Inspect the retainer and ball assembly for proper
openings.
17. Inspect the piston and seal assembly for cut seals or
other damage. The piston and seal assemblies are
reusable, if not damaged.
18. Clean and dry all of the components.

A103A142

FORWARD CLUTCH ASSEMBLE

Tools Required
J 41231 Inner Seal Installer
J 23327 Return Spring Compressor
1. Assemble a new inner seal assembly (608) if the old
seal was damaged and removed. Use an arbor press
and the J 41231 in order to press the inner seal as-
sembly onto the forward clutch housing (609).

A103A143

2. Assemble the forward clutch piston assembly (607)

into the forward clutch housing (609). In order to ease
assembly, lubricate the seals with transmission fluid.
3. With the snap ring tabs facing up, assemble the for-
ward clutch return spring assembly (606) into the for-
ward clutch housing (609).

A103A140

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 213
Important: In order to prevent damage to the spring as-
sembly (606), only compress the return spring assembly
(606) enough so that you can install the snap ring (605).
4. Compress the return spring assembly. Use the
J 23327.
5. Assemble the snap ring (605) in order to retain the
forward clutch return spring.
6. Remove the J 23327.

A103A139

7. Install the forward clutch waved plate (604).

8. Install the seven steel plates (603) and the seven
new fiber plates (602) in alternating order beginning
with a steel plate (603).
9. Install the forward clutch backing plate (601).
10. Install the forward clutch backing plate snap ring
(600) in order to retain the clutch pack.

A103A138

FORWARD CLUTCH FUNCTIONAL

AIR CHECK
Air check the forward clutch to verify proper operation
of the seals and clutch assembly.

A103A144

DAEWOO J-100 BL2 / BL3

5A -- 214 4T40-E AUTOMATIC TRANSAXLE

LOW/REVERSE BAND INSTALL

Install the low/reverse band (111) into the transmission
case (51). Align the servo pin apply surface toward the
bottom pan and hook the band into the band anchor pin
inside the transmission case (51).

A103A145

FORWARD CLUTCH INSTALLATION

Important: Rotate the forward clutch assembly (110)
counterclockwise during assembly in order to seat the
assembly into the lo roller clutch. When assembled cor-
rectly, the forward clutch assembly (110) should not turn
clockwise.
1. Install the forward clutch assembly (110) into the
transmission case (51).

A103A146

2. Insert a screwdriver through the reverse servo pin

hole in order to verify the correct installation of the lo/
reverse band (111). The screwdriver should com-
press the band around the forward clutch housing
(110).

A103A147

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 215

INPUT INTERNAL GEAR, FORWARD

CLUTCH HUB DISASSEMBLE
1. If the thrust washer (109) has not been removed, re-
move the thrust washer (109) from the forward clutch
hub (577).
2. Remove the input internal gear to forward clutch hub
assembly snap ring (578).
3. Remove the forward clutch hub (577) from the input
internal gear (560).

A103A148

4. Inspect the input internal gear for damage or exces-

sive wear.
5. Inspect the forward clutch hub splines for damage or
excessive wear.
6. Inspect the busing and the thrust washer for damage
or excessive wear.
7. Clean and dry all of the components.

A103A149

INPUT INTERNAL GEAR, FORWARD

CLUTCH HUB ASSEMBLE
Tools Required
J 36850 Transjelt
1. Assemble the forward clutch hub (577) onto the input
internal gear (560) and retain it with the snap ring
(578).
2. Assemble the thrust washer (109) onto the forward
clutch hub (577) with the thrust washer tabs toward
the forward clutch hub (577). Retain the thrust wash-
er with J 36850 or equivalent.

A103A148

DAEWOO J-100 BL2 / BL3

5A -- 216 4T40-E AUTOMATIC TRANSAXLE

INPUT INTERNAL GEAR, FORWARD

CLUTCH HUB INSTALL
Important: Install the forward clutch hub and input
internal gear assembly into the transmission case (51).
Rotate the assembly while installing in order to spline
the forward clutch hub (108) to the forward clutch plates
(602).
Install the forward clutch hub and input internal gear as-
sembly into the transmission case (51).

A103A150

REACTION INTERNAL GEAR, INPUT

CARRIER DISASSEMBLE
1. Remove the thrust bearing (107) from the reaction
carrier (562) if the thrust bearing has not been re-
moved.
2. Remove the reaction internal gear (560) to input carri-
er assembly snap ring (563).
Important: The reaction internal gear and the input in-
ternal gear are identical parts. However, these parts are
not interchangeable after the transmission has operated
in a vehicle.
3. Remove the input carrier assembly (562) from the
reaction internal gear (560).

A103A151

INPUT CARRIER PINION GEAR

CLEARANCE CHECK
Important: Replace the carrier if pinion gear clearance
is out of specification. The pinion gears are permanently
assembled to the carrier and are not serviced individual-
ly.
1. Measure the pinion gear end play for proper clear-
ance. Use a feeler gage. The clearance should be
0.24-0.69 mm (0.01-0.027 inch).
2. Inspect the reaction internal gear and the input carrier
assembly for damage or excessive wear. Specifically
inspect the condition of the pinion gears, the washers,
andthe thrust bearings.
3. Clean and dry each of the components.

A103A152

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 217

REACTION INTERNAL GEAR, INPUT

CARRIER ASSEMBLE
Tools Required
J 36850 Transjelt
1. Assemble the input carrier assembly (562) to the
reaction internal gear (560).
2. Retain the input carrier assembly with the snap ring
(563).
3. Assemble the thrust bearing (107) onto the input car-
rier assembly.
4. Retain the thrust bearing with J 36850 or equivalent.
You will find another thrust bearing permanently re-
tained in the input carrier assembly (562).

A103A151

REACTION INTERNAL GEAR, INPUT

CARRIER INSTALL
Important: While installing the reaction internal gear
and input carrier assembly, rotate the assembly in order
to mesh the input carrier pinion gears to the input inter-
nal gear.
Install the reaction internal gear and input carrier
assembly (106) into the transmission case (51).

A103A153

DIRECT/COAST CLUTCH, REACTION

CARRIER DISASSEMBLE
Tools Required
J 41232 Direct Clutch Return Spring
J 41236 Coast Clutch Return Spring Compressor
1. Remove the selective thrust bearing (103) and the
thrust washer (104) from the input shaft of the direct
and coast clutch assembly (105).

A103A154

DAEWOO J-100 BL2 / BL3

5A -- 218 4T40-E AUTOMATIC TRANSAXLE
2. Remove the input sun gear to input sun gear shaft
snap ring (534).
3. Remove the input sun gear (533) from the input sun
gear shaft (511).
4. Remove the thrust bearing (532) from the reaction
carrier assembly (531).

A103A155

5. Remove the reaction carrier assembly (531).You will

find a thrust bearing permanently installed in the reac-
tion carrier assembly under the pinion gears.
6. Remove the reaction sun gear and shell assembly
(529).
7. Remove the thrust bearing (527) from the reaction
carrier shaft and shell assembly (526).

A103A156

8. Remove the reaction carrier shaft and shell assembly

(526).
9. Remove the thrust bearing (524) from the top of the
sprag race assembly.

A103A157

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 219
10. Remove the sprag clutch retaining snap ring (517).
11. Remove the direct clutch plates from the direct
coast clutch input housing. The direct clutch con-
sists of a backing plate (523), steel plates (521) and
fiber plates (522).

A103A158

12. Lift up on the input sun shaft (511) in order to re-

move the input sun shaft (511) and the sprag (512)
as an assembly.
13. Remove the inner race to input housing thrust bear-
ing (510) if the inner race to input housing thrust
bearing did not remain with the input sun shaft and
sprag assembly.

A103A159

14. Remove the coast clutch plates from the input hous-
ing (502). The coast clutch consists of four steel
plates (508) and four fiber plates (509).

A103A160

DAEWOO J-100 BL2 / BL3

5A -- 220 4T40-E AUTOMATIC TRANSAXLE
15. Compress the direct clutch return spring assembly.
Use the J 41232.
16. Remove the spring retaining snap ring (520).
17. Remove the J 41232.

A103A161

18. Remove the direct clutch return spring (519).

19. Remove the direct clutch piston and seal assembly
(518).

A103A162

20. Compress the coast clutch return spring. Use the

J 41236.
21. Remove the spring retaining snap ring (507).
22. Remove the J 41236.

A103A163

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 221
23. Remove the coast clutch return spring retainer (506)
and the release spring (505).
24. Remove the coast clutch piston and seal assembly
(504).

A103A164

25. Remove and discard the four Teflont oil seals (500)
from the input shaft assembly (502).

A103A165

26. Remove the input sprag assembly (512-516) from

the input sun gear shaft (511).
27. Remove the snap ring (516) from the sprag assem-
bly (515).
28. Remove the sprag clutch assembly (515) from the
sprag outer race (513).
29. Remove the two end bearings (514) from the sprag
clutch assembly (515).

A103A166

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5A -- 222 4T40-E AUTOMATIC TRANSAXLE
Important: The pistons are reusable if not damaged. If
the pistons or seals are damaged, replace the assembly.
30. Inspect the piston (518 and 504) and seal assem-
blies for damage or cut seals.
31. Inspect the clutch spring (519) assemblies for dis-
tortion or missing springs.

A103A167

32. Inspect the direct clutch and coast clutch retainer

and ball assemblies for leaks or damage.
33. Inspect the oil passages for blockage.
34. Inspect the bushings and bearings for excessive
wear.
35. Inspect the seal grooves on the input shaft for nicks
or damage.
36. Inspect the splines, housings and clutch plates for
cracks, excessive wear or damage.
37. Inspect all other components for damage or exces-
sive wear.

A103A168

REACTION CARRIER PINION

CLEARANCE CHECK
Important: Replace the carrier assembly if the pinion
gear clearance is out of specification. The pinion gears
are permanently assembled to the carrier and are not
serviced individually.
1. Measure the reaction carrier pinion gear end play for
proper clearance. Use a feeler gauge. The clearance
is 0.24-0.69 mm (0.01-0.027 inch).
2. Clean and dry each of the components.

A103A169

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 223

DIRECT/COAST CLUTCH, REACTION

CARRIER ASSEMBLE
Tools Required
J 41236 Coast Clutch Return Spring Compressor
Adapter
J 41232 Direct Clutch Return Spring Compressor
Adapter
J 36850 Transjelt
J 41234-1 Input Shaft Seal Installer Pusher
J 41234-2 Input Shaft Seal Installer Protector
J 41234-3 Input Shaft Seal Installer Sizer
1. In order to aid in the assembly, lubricate the seal with
transmission fluid.
2. Assemble the coast clutch piston and seal assembly
(504) into the input housing (502).
A103A164
Important: You must assemble the spring retainer with
the inner lip facing up.
3. Assemble the coast clutch release spring (505) and
spring retainer (506) into the input housing (502).

4. Compress the coast clutch return spring retainer

(506). Use the J 41236.
5. Assemble the coast clutch spring retainer snap ring
(507) onto the input housing (502).
6. Remove the J 41236.

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5A -- 224 4T40-E AUTOMATIC TRANSAXLE
7. In order to aid in the assembly, lubricate the seal
with transmission fluid.
8. Assemble the direct clutch piston and seal assembly
(518) into the input housing (502).
9. Assemble the direct clutch return spring assembly
(519) into the input housing with the snap ring retain-
ing tabs facing up.

A103A162

10. Compress the direct clutch spring assembly. Use

the J 41232.
11. Assemble the direct clutch snap ring (520) into the
input housing (502).
12. Remove the J 41232.

A103A161

Important: Assemble the steel plates (508) with the

splines in the input housing groove that are machined to
the pistons.
13. Assemble the 4 steel coast clutch plates (508) and
the 4 new fiber coast plates (509) into the input
housing in alternating order beginning with a steel
plate (508).

A103A160

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 225
14. Place the sprag outer race (512) on the bench with
the flat side down and the side with the snap ring
groove up.
15. Place one end bearing (514) into the outer race.
16. While rotating the sprag slowly, assemble the sprag
clutch (515) into the sprag outer race. Keep the
grooved edge up and the flat side down.
17. Assemble the other end bearing (514) on top of the
sprag clutch.
18. Assemble the snap ring (516) into the sprag outer
race (512) in order to retain the sprag clutch and end
bearings.
Important: The snap ring side of the assembly faces up
when installing the sprag clutch onto the input sun shaft.
The flat side of the sprag outer race functions as the
backing plate for the coast clutch.
A103A166 19. While rotating the input sun shaft clockwise in order
to help seat the sprags, assemble the sprag clutch
and outer race assembly onto the input sun shaft
(511).

Important: The input sun shaft (511) must only rotate

clockwise.
20. Verify the correct operation of the sprag clutch
by holding the sprag clutch outer race (512) and
rotating the input sun shaft (511).

A103A170

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5A -- 226 4T40-E AUTOMATIC TRANSAXLE
21. Assemble the thrust bearing (510) on the underside
of the input sun shaft.
22. Retain the thrust bearing with J 36850 or equivalent.
23. Assemble the input sun shaft and sprag clutch as-
sembly (511 and 512) into the input housing. The
splines on the input sun shaft engage with the coast
clutch fiber plates.

A103A159

24. Assemble the steel (521) and new fiber (522) direct
clutch plates into the input housing in alternating or-
der beginning with a steel plate (521).
25. Assemble the direct clutch backing plate (523) onto
the input housing with the flat side down.
26. Assemble the snap ring (517) in order to retain the
input sun shaft and sprag clutch assembly and the
direct clutch plates.

A103A158

27. Assemble the thrust bearing (524) on the top of

the sprag clutch assembly. Retain with J 36850 or
equivalent.
28. Assemble the reaction carrier shaft and shell as-
sembly (526) onto the input housing. The splines on
the inside of the shell engage the direct clutch fiber
plates.

A103A157

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 227
29. Assemble the thrust bearing (527) onto the top of
the reaction carrier shaft and shell assembly.
30. Assemble the reaction carrier sun gear and shell as-
sembly (529) onto the reaction shaft shell.
Important: Rotate the reaction carrier during assembly
in order to mesh the sun gear with the pinion gears.
31. Assemble the reaction carrier assembly (531) onto
the reaction sun gear.

A103A156

32. Assemble the reaction carrier assembly to input sun

gear thrust bearing (532) onto the reaction carrier
assembly.
33. Assemble the input sun gear (533) onto the input
sun shaft.
34. Assemble the input sun gear snap ring (534) onto
the input sun shaft.

A103A155

Important: When assembling the four new Teflont

seals (500) onto the input shaft, begin with the seal clos-
est to the housing.
35. Slide the J 41234-1 over the input shaft, and posi-
tion the J 41234-1 at the seal groove closest to the
housing. Coat the J 41234-1 with transmission fluid.
36. Guide a new seal onto the J 41234-1 and slide the
seal into the seal groove with the J 41234-2.
37. Repeat the above procedure for each seal. Adjust
the J 41234-1 as necessary for each seal groove.

A103A171

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5A -- 228 4T40-E AUTOMATIC TRANSAXLE
38. Size the seals with the J41234-3.
39. Leave the J 41234-3 in place for at least five min-
utes. If possible, leave the J 41234-3 in place until
when you install the assembly into the transmission
case.

A103A172

DIRECT AND COAST CLUTCH

FUNCTIONAL AIR CHECKS
1. Air check the direct clutch in order to verify the proper
operation of the seals and clutch assembly.
2. Air check the coast clutch in order to verify the proper
operation of the seals and clutch assembly.

A103A173

DIRECT/COAST CLUTCH, REACTION

CARRIER INSTALL
Install the direct/coast clutch and reaction carrier as-
sembly (105) into the transmission case (51).

A103A174

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 229

SELECTIVE WASHER
MEASUREMENT AND INSTALLATION
Tools Required
J 34673 Gage Block
1. Place the J 34673 across the machined surface of
the case.
2. Measure the distance between the top of the direct/
coast clutch housing (105) and the machined surface
of the case (Dimension A).
3. Note the measurement of Dimension A and choose
the correct selective washer. Refer to Selective
Washer Table in End Play Specifications.
Important: Position the tab on the thrust washer in the
recessed area for the retainer and ball assembly (104).
4. Assemble the selective washer (104) onto the top of
A103A175
the input housing.
5. Assemble the thrust bearing (103) over the input
shaft and onto the top of the selective thrust washer
(104).

REVERSE INPUT AND 2ND ROLLER

CLUTCH DISASSEMBLE
Tools Required
J 41232 Return Spring Compressor
J 41097-1 Inner Seal Remover Adapter
J 41097-2 Inner Seal Remover Adapter Ring
J 25031-A Inner Seal Remover
J 4646 Internal Snap Ring Pliers
1. Remove the reverse clutch snap ring (464).
2. Remove the reverse clutch plates (one backing plate
(463)l, three steel plates (461), three fiber plates
(462), and a waved plate (460)).

A103A176

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5A -- 230 4T40-E AUTOMATIC TRANSAXLE
3. Compress the reverse clutch return spring. Use the
J 41232.
4. Remove the reverse clutch return spring and the re-
tainer snap ring (459).
5. Remove the J 41232.

A103A177

6. Remove the reverse clutch return spring and retainer

assembly (458).
7. Remove the reverse clutch piston and seal assembly
(457).

A103A178

Important: If the seal assembly is not damaged do not

remove the seal assembly.
8. Inspect the reverse clutch inner seal (456).
9. If the seal assembly is damaged, perform the follow-
ing procedure in order to remove the seal assembly:
9.1. Attach the J 41097-1 (not shown in the il-
lustration) to the J 41097-2.
9.2. Place the J 41097-2 on the inner hub of the
reverse clutch housing (454).
9.3. Use the J 4646 or equivalent in order to install
the J 41097-2 under the outer lip of the re-
verse clutch inner seal (456).
9.4. Use the puller J 25031-A in order to remove
the seal.

A103A179

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 231
Important: Be careful when removing the second roller
clutch not to score the roller clutch inner race with the
screwdrivers.
10. Remove the 2nd roller clutch (452) and roller clutch
retainer (450) by prying up on the roller clutch as-
sembly with two screwdrivers. The second roller
clutch retainer is pressed onto the reverse clutch
housing (454) and is not reusable after removal.

A103A180

11. Remove the 2nd roller clutch (452) from the inside of
the roller clutch cam (451).

A103A181

12. Inspect the reverse housing for excessive band

wear and damaged splines.
13. Inspect the retainer and ball capsule for damage or
clogging.
14. Inspect the fluid feed holes for proper opening.

A103A182

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5A -- 232 4T40-E AUTOMATIC TRANSAXLE
15. Inspect the roller clutch for excessive wear (451 and
452).
16. Inspect the spring assembly for dislocated or dam-
aged springs (458).
17. Inspect all components for damage and excessive
wear.
18. Clean and dry each of the components.

A103A183

REVERSE INPUT AND 2ND ROLLER

CLUTCH ASSEMBLE
Tools Required
J 41232 Return Spring Compressor
J 41233 Inner Seal Installer
1. If the reverse clutch inner seal assembly (456) was
damaged and removed, install a new reverse clutch
inner seal assembly (456). Use the J 41233.
2. Assemble the reverse clutch piston and seal assem-
bly (457). In order to aid in the assembly, lubricate the
seal with transmission fluid.
3. Assemble the reverse clutch return spring and retain-
er assembly (458) with the smaller outside diameter
down.

A103A184

4. Compress the reverse clutch return spring. Use the

J 41232.
5. Assemble the return spring snap ring (59).
6. Remove the J 41232.

A103A177

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 233
7. Assemble the wave plate (460).
8. Assemble the three steel plates (461) and the three
new fiber plates (462) in alternating order beginning
with a steel plate (461).

A103A176

9. Measure the distance between the top of the snap

ring groove and the top friction plate (Dimension A).
10. In order to select the appropriate backing plate,
use Dimension A. You will find the backing plate
identification stamped onto the beveled side of the
backing plate. Refer to the Reverse Clutch Table in
Transaxle General Specifications.
11. Assemble the reverse clutch backing plate (463)
with the beveled edge up.
12. Assemble the snap ring (464) in the reverse clutch
housing in order to retain the reverse clutch plates.

A103A185

REVERSE CLUTCH FUNCTIONAL AIR

CHECK
Tools Required
J 41235 Second Roller Clutch Installer
1. Air check the reverse clutch in order to verify the
proper operation of the seals and clutch assembly.

A103A186

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5A -- 234 4T40-E AUTOMATIC TRANSAXLE
2. Assemble the 2nd roller clutch assembly (452) into
the roller clutch cam (451).
Important: When installing the 2nd roller clutch assem-
bly onto the reverse clutch housing, the flat side of the
roller clutch cam faces down toward the housing (454).
3. While rotating the roller clutch in order to properly en-
gage the rollers, assemble the 2nd roller clutch onto
the reverse clutch housing (454).

A103A181

Important: The J 41235 will press the roller clutch as-

sembly to a specified depth. If you install the 2nd roller
too far down onto the inner race, the roller clutch may
not operate properly.
4. Assemble a new 2nd roller clutch retainer (450) onto
the 2nd roller clutch assembly. Use the J 41235 in or-
der to press the retainer and roller clutch assembly
into place on the reverse clutch housing and roller
clutch inner race.

A103A187

5. Hold the reverse clutch housing and ensure that the

roller clutch cam rotates clockwise only.

A103A188

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 235

REVERSE INPUT AND 2ND ROLLER

CLUTCH INSTALL
Important: The tangs on the reverse clutch housing
spline to the tangs on the reaction carrier sun gear and
shell assembly.
1. While rotating the reverse clutch housing in order to
align the clutch plates, install the reverse clutch and
2nd roller clutch assembly into the transmission case.
2. Assemble the reverse clutch thrust washer (101) onto
the top of the 2nd roller clutch. The tabs must face
down onto the housing.

A103A189

INTERMEDIATE 4TH BAND

ASSEMBLY INSTALL
1. Assemble a new intermediate/fourth band (100) into
the transmission case (51).

A103A190

2. In order to verify the proper positioning of the band,

insert a screwdriver through the intermediate/fourth
servo bore. The screwdriver should press on the ser-
vo pin rest and compress the band around the re-
verse clutch housing.

A103A191

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5A -- 236 4T40-E AUTOMATIC TRANSAXLE

2ND CLUTCH PLATE INSTALLATION

1. Inspect the 2nd clutch plates for excessive wear.
2. Clean and dry each of the components.
3. Assemble the 2nd clutch backing plate (99) with the
flat side facing up.
4. Assemble the three steel (97) and the three new fiber
plates (98) in alternating order beginning with a fiber
plate (98).
5. Assemble the 2nd clutch wave plate (96).

A103A192

DRIVEN SPROCKET ASSEMBLY

DISASSEMBLE
Tools Required
J 41232 Return Spring Compressor
1. Remove the two seal rings (403) from the driven
sprocket support.
2. Discard the two seal rings (401).

A103A201

3. Compress the 2nd clutch spring and retainer assem-

bly (405). Use the J 41232.
4. Remove the 2nd clutch spring retainer snap ring
(406).
5. Remove the J 41232.

A103A193

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 237
6. Remove the 2nd clutch spring and retainer assem-
bly (405).
7. Remove the 2nd clutch piston and seal assembly
(404). If not damaged, the piston and seal assembly
is reusable.

A103A194

8. Inspect the piston and seal assembly for damaged

seals.
9. If the seal is cut or damaged replace the seal with a
new piston and seal assembly.

A103A195

10. Inspect the bushing and bearing for damage or ex-

cessive wear.
11. Inspect the driven sprocket support for plugged feed
holes, damaged seal grooves, stripped bolt holes,
and a damaged machined surface.

A103A196

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5A -- 238 4T40-E AUTOMATIC TRANSAXLE
12. Inspect the reverse intermediate clutch housing
valve assembly (407) for free operation.
Important: The valve assembly must be in its seated
position before you perform the leak test.
13. Using automatic transmission fluid, inspect the re-
verse intermediate clutch housing valve assembly
(407) for leaks.

A103A197

Important: Remove the reverse clutch housing valve

assembly (407) only if inspection or the leak test has in-
dicated a problem.
14. Using a 6.25 mm (1/4 inch) drift and a mallet, re-
move the valve assembly (407) from the driven
sprocket support (401).

A103A198

15. Using a 6.25 mm (1/4 inch) drift and a mallet, install

the valve assembly (407) in the driven sprocket sup-
port (401).

A103A199

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 239
16. Inspect the spring assembly for dislocated or dam-
aged springs.
17. Clean and dry each of the components.

A103A195

DRIVE SPROCKET SUPPORT

ASSEMBLE
Tools Required
J 41232 Return Spring Compressor
1. In order to aid in the assembly, lubricate the seal with
transmission fluid.
2. Assemble the 2nd clutch piston and seal assembly
(404) into the driven sprocket support (401).
3. Assemble the 2nd clutch spring and retainer assem-
bly (405) into the driven sprocket support.

A103A200

4. Compress the 2nd clutch spring assembly. Use the

J 41232.
5. Assemble the 2nd clutch spring retainer snap ring
(406).
6. Remove the J 41232.

A103A193

DAEWOO J-100 BL2 / BL3

5A -- 240 4T40-E AUTOMATIC TRANSAXLE
7. Assemble two new seal rings (403) onto the driven
sprocket support.

A103A201

2ND CLUTCH FUNCTIONAL AIR

CHECK
Air check the 2nd clutch in order to verify proper
operation of the seals and clutch assembly.

A103A202

DRIVEN SPROCKET SUPPORT

ASSEMBLY INSTALLATION
Install the driven sprocket support and 2nd clutch as-
sembly (95) into the transaxle case (51). When installed
properly, the driven sprocket support sits
slightly below the machined surface of the transaxle
case (51).

A103A203

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 241

WIRING HARNESS INSTALLATION

1. Inspect the wiring harness (11) for damage.
2. Inspect the pass thru connector pins and O-ring seal
for damage.
3. Assemble the wiring harness pass thru connector into
the transaxle case bore from the inside of the trans-
axle case.

A103A204

INPUT SPEED SENSOR INSTALL

Important: The tab on the sensor housing (46) fits into
the recess on the case boss.
Important: For drive sprockets with 35 teeth, use a
black sensor housing. For drive sprockets with 32 or
33 teeth, use a natural colored sensor housing.
1. Assemble the input speed sensor (46) to the trans-
mission case (51).
2. Install the input speed sensor bolt (15). Hand start
and tighten the input speed sensor bolt to 12 NSm
(9 lb-ft).
3. Route the input speed sensor wiring harness in the
case channel.
4. Connect the input speed sensor connector to the in-
put speed sensor.
A103A095 5. Install the wire harness retainer and wire harness re-
tainer bolt. Tighten the wire harness retainer bolt
to 12 NSm (9 lb-ft).

DAEWOO J-100 BL2 / BL3

5A -- 242 4T40-E AUTOMATIC TRANSAXLE

DRIVE, DRIVEN SPROCKETS AND

DRIVE LINK DISASSEMBLE
1. Remove the turbine shaft to drive sprocket snap ring
(35).
2. Remove the drive sprocket (37) from the turbine shaft
(39).
3. Remove the three Teflont seals (33 and 40) from the
turbine shaft.
4. Discard the Teflont seals (33 and 40).

A103A205

5. Inspect the drive sprocket, the driven sprocket, the

drive link assembly, and the turbine shaft for damage
or excessive wear.
6. Inspect the seal grooves for damage.
7. Inspect the thrust washers for damage or excessive
wear.
8. Clean and dry each of the components.

A103A206

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 243

DRIVE, DRIVEN SPROCKETS AND

DRIVE LINK ASSEMBLE
Tools Required
J 29569-1/J 29829-1 Turbine Shaft Seal Installer
J 29569-2/J 29829-2 Turbine Shaft Seal Sizer
1. In order to assemble three new Teflont seals onto
the turbine shaft, perform the following procedure:
1.1. Slide both halves of the J 29569-1/J 29829-1
over the turbine shaft.
1.2. Coat the J 29569-1/J 29829-1 with transmis-
sion fluid.
1.3 Use your fingers in order to guide the new Tef-
lont seals over the J 29569-1/J 29829-1 and
into the seal ring grooves on the turbine shaft.
1.4. Remove the J 29569-1/J 29829-1 when the
A103A207 seals are in place.
1.5. Size the new Teflont seals. Use both halves
of the J 29569-2/J 29829-2.
1.6. In order to properly size the seals, keep the
J 29569-2/J 29829-2 in place for five minutes.

2. Assemble the drive sprocket (37) onto the turbine

shaft (39).
3. Retain the drive sprocket with the turbine shaft to
drive sprocket snap ring (35).

A103A208

DAEWOO J-100 BL2 / BL3

5A -- 244 4T40-E AUTOMATIC TRANSAXLE

DRIVE, DRIVEN SPROCKETS AND

DRIVE LINK INSTALL
Tools Required
J 36850 Transjelt
1. Install the drive sprocket to drive sprocket support
thrust washer (38) to the drive sprocket (37). Place
the tabs on the thrust washer into the holes on the
drive sprocket.
2. Retain the thrust washer with J 36850 or equivalent.
3. Install the driven sprocket to driven sprocket support
thrust washer (92) onto the driven sprocket support
(95).
Important: Orient the drive link assembly (36) in the
same direction in which the drive link assembly (36) was
removed. If the drive link assembly (36) is new, you can
A103A209 install it in either direction.
4. Install the drive link assembly (36) to the drive and
driven sprockets (37 and 91).
5. Install as a complete assembly, the drive sprocket
(37), the driven sprocket (91), and the drive link as-
sembly (36) onto the transmission.

CHANNEL PLATE ASSEMBLY

DISASSEMBLE
Important: The accumulator pins are pressed into the
channel plate (27). Do not remove the accumulator pins.
1. Remove the three accumulator pistons (29) from the
channel plate (27).
Important: The 1-2 accumulator assist spring (125) has
a retainer that presses into the spring. Keep the retainer
and the spring together as an assembly.
2. Remove the 1-2 accumulator assist spring 9125).
3. Remove the 2-3 accumulator assist spring (47).
4. Remove the seals (30) from the accumulator pistons
(29).
5. Discard the accumulator piston seals (30).
6. Remove the manual valve (800) from the channel
A103A210 plate (27).

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 245
7. Inspect the channel plate (27) for damage.
8. Inspect the channel plate (27) passages for debris.
9. Inspect the accumulator pistons (29), the assist
springs (47 and 125), and the pins for damage.
10. Inspect the channel plate sleeve for wear from the
turbine shaft.
11. Inspect the channel plate (27) bolt holes for stripped
threads and debris.
12. Inspect the channel plate machined surface for
nicks or scratches that could cause a fluid leak.
13. Inspect the manual valve (800) for freedom of
movement.
14. Inspect the drive sprocket to channel plate thrust
washer (34).
15. Clean and dry each component.

A103A211

CHANNEL PLATE ASSEMBLY

ASSEMBLE
Tools Required
J 36850 Transjelt
1. Assemble the new accumulator piston seals (30) on
the three accumulator pistons (29).
2. Install the 1-2 and 2-3 accumulator assist springs
(47 and 125).
3. Install the accumulator pistons (29) into the channel
plate over the guide pins. The pistons are identical.
You can assemble the pistons in any of the three ac-
cumulator bores.
4. In order to retain the pistons, apply J 36850 onto the
piston seals.

A103A210

ACCUMULATOR SPRINGS INSTALL

Important: The 1-2 accumulator spring (31) is slightly
taller than the other two springs (32). Install a 1-2
accumulator spring in the bore closest to the electrical
pass-through connector (11).
Install the two remaining accumulator springs into the
transmission case accumulator bores.

A103A092

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5A -- 246 4T40-E AUTOMATIC TRANSAXLE

CHANNEL PLATE ASSEMBLY

INSTALLATION
Tools Required
J 36850 Transjelt
1. Install the channel plate to drive sprocket thrust
washer (34) onto the channel plate (27).
2. Retain the thrust washer (34) with J 36850 or equiva-
lent.
3. Install a new channel plate to case gasket (28) onto
the transmission case (51).
4. Install the channel plate assembly onto the transmis-
sion case (51). The channel plate should fit tightly
over the guide pins (45) located on the transmission
case (51).
Important: Tighten the two channel plate bolts (25) to
A103A212 14 NSm (10.5 lb-ft).
5. Install the eight channel plate to case bolts (8 and 25)
and the two channel plate to driven sprocket support
bolts (25). Hand tighten the bolts and tighten to either
12 NSm (9 lb-ft) or 14 NSm (10.5 lb-ft).

MANUAL VALVE INSTALL

1. Install the manual valve (800) into the channel plate.
2. Connect the manual valve link (802) to both the
manual valve and detent lever.
3. Install the manual valve clip (801) onto the manual
valve.

A103A090

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 247

CHECKBALLS INSTALLATION
Install the seven checkballs into the proper locations on
the channel plate.

A103A089

SPACER PLATE AND GASKETS

INSTALL
1. Inspect the spacer plate and spacer plate filter for
damage.
2. If damaged, replace the spacer plate and spacer
plate filter.

A103A213

3. Install a new spacer plate to channel plate gasket (24)

onto the channel plate.
4. Install the spacer plate (23) on top of the gasket and
channel plate.
5. Install the spacer plate support (21) and the two bolts
(20) onto the spacer plate. Hand start and then
tighten the bolts to 14 NSm (10.5 lb-ft).

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5A -- 248 4T40-E AUTOMATIC TRANSAXLE

CONTROL VALVE BODY

DISASSEMBLE
Important: Retainer clips hold in each of the valve line-
ups. Use a small screwdriver in order to remove the re-
tainer clips. Be careful not to score the valve body when
removing the retainer clips and valves. Before removing
the valve line-ups, inspect each valve line-up for free-
dom of movement.
1. Remove the 3-4 shift valve retainer clip (304), the
bore plug (321), with O-ring (320), the 3-4 shift valve
(319) and the 3-4 shift valve spring (318).

A103A214

2. Remove the actuator feed limit valve retainer clip

(304), the bore plug (317), the actuator feed limit
spring (316) and the actuator feed limit valve (315).

A103A215

3. Remove the actuator oil filter retainer clip (304) and

the actuator oil filter (324) with O-ring (313).

A103A216

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 249
4. Remove the Pressure Control Solenoid (PCS) retain-
er clip (304), the PCS with two O-rings and screen
(312, 309, and 310), the torque signal regulator valve
(309), and the torque signal regulator spring (308).

A103A217

5. Remove the 2-3 shift solenoid retainer clip (304), the

2-3 shift solenoid (305) with O-ring (303), the 2-3 shift
valve (307), and the 2-3 shift valve spring (306).

A103A218

6. Remove the 1-2 shift solenoid retainer clip (304), the

1-2 shift solenoid (305) with O-ring (303), the 1-2 shift
valve (302), and the 1-2 shift valve spring (301).

A103A219

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5A -- 250 4T40-E AUTOMATIC TRANSAXLE
7. Remove the TCC solenoid retainer clip (304), the
TCC solenoid (335) with two O-rings (337 and 338)
and screen, the TCC regulated apply valve (339) and
the spring (340).

A103A220

8. Remove the TCC control valve retainer clip (304), the

bore plug (317), the spring (333), and the TCC control
valve (334).

A103A221

9. Remove the TCC feed limit valve retainer clip (304),

the bore plug (317), the spring (331), and the TCC
feed limit valve (332).

A103A222

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 251
10. Remove the 2-3 accumulator valve retainer clip
(304), the 2-3 accumulator valve bore plug (317),
the 2-3 accumulator valve spring (329), and the 2-3
accumulator valve (330).

A103A223

11. Remove the pressure regulator valve retainer clip

(304), the bushing (324), the pressure regulator
boost valve (325), the isolator spring (326), the pres-
sure regulator valve spring (327), and the pressure
regulator valve (328).

A103A224

12. Remove the 1-2/3-4 accumulator valve retainer clip

(304), the plug (317), and the accumulator valve
(323).
13. Inspect the valve body passages for debris.
14. Inspect the machined surfaces for nicks or
scratches. Some polish is normal for the machined
surfaces.
15. Inspect the valves for nicks or scratches that could
cause sticking valves or fluid leaks.
16. Inspect the springs, bushings, O-rings, screens and
solenoids for damage.
17. Clean and dry the valve body and valve body
components.

A103A225

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5A -- 252 4T40-E AUTOMATIC TRANSAXLE

CONTROL VALVE BODY ASSEMBLE

1. Install the 1-2 shift valve spring (301), the 1-2 shift
valve (302), the 1-2 shift solenoid (305) with O-ring
(303), and the 1-2 shift solenoid retainer clip (304).

A103A219

2. Install the 2-3 shift valve spring (306), the 2-3 shift
valve (307), the 2-3 shift solenoid (305) with O-ring
(303), and the 2-3 shift solenoid retainer clip (304).

A103A218

3. Install the torque signal regulator spring (308), the

torque signal regulator valve (309), the Pressure
Control Solenoid (PCS) with two O-rings and screen
(312, 309 and 310), and the PCS retainer clip (304).

A103A217

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 253
4. Install the actuator oil filter (324) with the O-ring (313)
and the actuator oil filter retainer clip (304).

A103A216

5. Install the actuator feed limit valve (315), the actuator

feed limit spring (316), the bore plug (317), and the
actuator feed limit valve retainer clip (304).

A103A215

6. Install the 3-4 shift valve spring (318), the 3-4 shift
valve (319), the bore plug (321), with O-ring (320),
and the 3-4 shift valve retainer clip (304).

A103A214

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5A -- 254 4T40-E AUTOMATIC TRANSAXLE
7. Install the accumulator valve (323), the plug (317),
and the 1-2/3-4 accumulator valve retainer clip (304).

A103A225

8. Install the pressure regulator valve (328), the pres-

sure regulator valve spring (327), the isolator spring
(326), the pressure regulator boost valve (325), the
bushing (324), and the pressure regulator valve re-
tainer clip (304).

A103A224

9. Install the 2-3 accumulator valve (330), the 2-3 accu-

mulator valve spring (329), the 2-3 accumulator valve
bore plug (317), and the 2-3 accumulator valve retain-
er clip (304).

A103A223

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 255
10. Install the TCC feed limit valve (332), the spring
(331), the bore plug (317), and the TCC feed limit
valve retainer clip (304).

A103A222

11. Install the TCC control valve (334), the spring (333),
the bore plug (317), and the TCC control valve re-
tainer clip (304).

A103A221

12. Install the spring (340), the TCC regulated apply

valve (339), the TCC solenoid (335) with two O-
rings (337 and 338) and screen, and the TCC sole-
noid retainer clip (304).

A103A220

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5A -- 256 4T40-E AUTOMATIC TRANSAXLE

CONTROL VALVE ASSEMBLY AND

TFP SWITCH INSTALL
1. Install the control valve body assembly to spacer
plate gasket (22) onto the spacer plate (23).
2. Install the control valve body assembly (18) onto the
transmission.

A103A067

3. Inspect the TFP switch (13) in order to verify the con-

dition and correct location of the seven pressure
switch O-rings.
4. If necessary, replace the pressure switch O-rings.

A103A226

5. Install the TFP switch (13) onto the control valve as-
sembly.

A103A086

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 257
6. Install the eighteen control valve assembly bolts.

A103A227

7. Hand start the bolts, then tighten the bolts to 12 NSm

(9 lb-ft).

A103A228

WIRING HARNESS ASSEMBLY

CONNECT
Connect the wiring harness assembly to the following
components:
D The TFP switch (13)
D The pressure control solenoid (312) (red connector)
Important: The 1-2 shift solenoid wires are red and light
green. The 2-3 shift solenoid wires are red and yellow.
D The 1-2 shift solenoid (305) (white connector)
D The 2-3 shift solenoids (305) (white connectors)
D The TCC solenoid (335)

A103A085

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5A -- 258 4T40-E AUTOMATIC TRANSAXLE

OIL PUMP CLEAN AND INSPECT

1. Inspect the bearing on the flange for excessive wear
or damage.
2. Inspect the machined surfaces for scratches or nicks
that may cause a fluid leak.
Important: While flushing, rotate the oil pump rotor with
the oil pump drive shaft. Rotating the oil pump rotor
flushes clean fluid through the oil pump.
3. Thoroughly flush the oil pump with clean transmission
fluid through the pump inlet and outlet passages.
4. Drain excess fluid from the oil pump assembly.

A103A229

OIL PUMP ASSEMBLY

INSTALLATION
1. Install the oil pump shaft (19) into the control valve
body assembly (18).
Important: If necessary, rotate the oil pump shaft while
installing the oil pump assembly in order to engage the
shaft splines to the splines on the pump rotor.
2. Install oil pump assembly (10) onto the oil pump shaft
(19) and control valve body (20).
3. Install the eight oil pump bolts (8, 9 and 12). Hand start
the bolts, then tighten the bolts to 12 NSm (9 lb-ft.)

A103A084

SIDE COVER/GASKETS,
DISASSEMBLE, ASSEMBLE,
INSTALL
Tools Required
J 36850 Transjelt
1. Remove the side cover gaskets (5 and 6) and the
thrust washer (17) from the side cover (1).

A103A230

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 259
Important: Do not score or damage the side cover bore.
2. Remove the side cover axle seal. Use the handle
end of a hammer.

A103A231

3. Inspect the side cover for cracks or damage to the

seal grooves and mounting bosses.
4. Inspect the side cover seals for damage. The side
cover seals are reusable if not damaged.
5. Thoroughly clean the side cover and the side cover
seals.
6. Clean and dry the seal grooves and the axle seal
bore.
7. Install the side cover gaskets (5 and 6) into the
grooves on the side cover (1).
8. Retain the seals with J 36850 or equivalent.
9. Install the side cover to drive sprocket thrust washer
(7) onto the side cover.
10. Retain the thrust washer with J 36850 or equivalent.

A103A230

11. Install the side cover assembly onto the transmis-

sion case (51).
12. Install the 11 side cover bolts (3) and one stud (4).

A103A232

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5A -- 260 4T40-E AUTOMATIC TRANSAXLE
13. Refer to the graphic in order to find the correct
installation points of the bolts and the stud.

A103A233

14. Hand start and then tighten the side cover bolts and
stud to 20 NSm (15 lb-ft).

A103A234

OUTPUT SHAFT SLEEVE ASSEMBLE

Tools Required
J 41228 Output Shaft Sleeve Installer
1. Inspect the output shaft (94) for damage to the
splines, snap ring grooves and the journals.
2. Clean and dry the output shaft.

A103A235

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 261
Important: You must use the J 41228 in order to install
the sleeve onto the output and stub shafts. If you do not
use the J 41228, you will cause a fluid leak.
3. Place a sleeve (56) over the end of the output shaft
(94).
4. Install the collet into the output shaft snap ring groove
with the collet attached to the threaded collet shaft.
5. Place the sleeve installing tube over the collet. Be
sure the small outside diameter of the tube fits se-
curely into the sleeve.
6. Install the bearing and nut onto the threaded collet
shaft.
7. In order to move the installing tube and press the
sleeve onto the output shaft, hold the end of the
threaded collet shaft while tightening the nut down.
8. Remove the J 41228.
A103A236

OUTPUT SHAFT AND SLEEVE

ASSEMBLY INSTALL
1. Install the two new snap rings (57) into the output
shaft (94) snap ring grooves.
2. Install the output shaft and sleeve assembly (94 and
56) into the transmission case. Use a mallet in order
to install the shaft (94) through the final drive differen-
tial gear.

A103A237

SIDE COVER AXLE SEAL INSTALL

Tools Required
J 41102 Axle Seal Installer
Important: You must use the J 41102 in order to install
the seal correctly. The J 41102 installs the axle seal to a
given depth.
1. Install a new side cover axle seal (2) into the side cov-
er. Use the J 41102.
2. In order to prevent damage to the shaft splines during
vehicle operation, add Polyurea grease (part num-
ber 7843867) to the splines on the output shaft.

A103A238

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5A -- 262 4T40-E AUTOMATIC TRANSAXLE

STUB SHAFT SLEEVE ASSEMBLE

AND INSTALL
1. Inspect the stub shaft (58) for damage to the splines,
the snap ring grooves, and the journals.
Important: If the sleeve (56 appears damaged, replace
the sleeve (56) using the same procedure for removal
and installation as with the output shaft sleeve. Refer to
Output Shaft and Sleeve Assembly Install.
2. Inspect the sleeve (56) for excessive wear, scratches
or nicks that could cause a leak or damage the seal
portion.
3. Clean and dry the stub shaft and sleeve assembly.

A103A239

4. Install the two new snap rings (57) on the stub shaft
(58). The snap rings (57) are not reusable after you
remove the shaft (58).
5. Install the stub shaft into the transmission. Use a mal-
let in order to install the shaft through the final drive
differential gear.

A103A240

RIGHT HAND AXLE SEAL

ASSEMBLE
Tools Required
J 41102 Axle Seal Installer
Important: You must use the J 41102 in order to install
the seal correctly. The J 41102 installs the axle seal to a
given depth.
1. Install a new right hand axle seal (2) into the trans-
mission case. Use the J 41102.
2. In order to prevent damage to the shaft splines during
vehicle operation, add Polyurea grease (part number
(7843867) to the splines on the output shaft.

A103A241

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 263

OUTPUT SPEED SENSOR

INSTALLATION
1. Inspect the output speed sensor (62) for damage to
the sensor, the electrical connector, or the O-ring
(63).
2. Clean and dry the output speed sensor (62).

A103A242

3. Install the O-ring (63) onto the output speed sensor

(62).
4. Install the output speed sensor (62) into the trans-
mission case.
5. Install the output speed sensor stud (61). Tighten the
output speed sensor stud to 12 NSm (9 lb-ft).

A103A243

INTER 4TH SERVO DISASSEMBLE,

ASSEMBLE, AND INSTALL
1. Remove the piston and pin assembly (76 and 77)
from the servo cover (80).
2. Remove the snap ring (70) from the servo pin (76).
3. Remove the piston (77) and servo cushion springs
(68) from the servo pin (76).
4. Remove the outer (78) and inner (79) servo piston
seal from the cover (80).
5. Discard the outer and inner servo piston seals. Do not
reuse the servo piston seals.

A103A244

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5A -- 264 4T40-E AUTOMATIC TRANSAXLE
6. Inspect all components for damage.
7. Inspect the fluid feed holes for proper opening.
8. Inspect the bolt hole threads for debris and strip-
ping.
9. Inspect the seal grooves for damage.
10. Clean and dry each component.

A103A244

11. Install the servo cushion springs (68) and the servo
piston (77) onto the servo pin (76).
12. Install the snap ring (70) onto the servo pin (76) in
order to retain the springs (68) and piston (77).
13. Install the new seals (78 and 79) onto the servo pis-
ton (77) and servo cover (80).
14. Install the servo piston assembly into the servo cov-
er (80). Lubricate the piston seals with transmission
fluid in order to aid in assembly.

A103A244

15. Install the servo return spring (75) onto the trans-
mission case (51).
16. Install the servo cover (80) and the piston assembly
over the servo return spring (75).
17. Install the three servo cover bolts (25). Hand start
the bolts and then tighten the bolts to 12 NSm (9 lb-
ft).

A103A081

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 265

LOW/REVERSE SERVO ASSEMBLY

DISASSEMBLE
1. Remove the piston pin assembly (67-70) from the
servo cover (73).
2. Remove the snap ring (70) from the servo pin (67).
3. Remove the piston (69) and the servo cushion
springs (68) from the servo pin (67).
4. Remove the servo piston seals (71 and 72) from the
cover (73).
5. Discard the servo piston seals (71 and 72).
6. Inspect all the components for damage.
7. Inspect the fluid feed holes for the proper opening.
8. Inspect the bolt hole threads for debris or stripping.
9. Inspect the seal grooves for damage.
10. Clean and dry each component.
A103A245

LOW/REVERSE SERVO ASSEMBLY

ASSEMBLE
1. Assemble the servo cushion springs (68) and servo
piston (69) onto the servo pin (67).
2. Install the snap ring onto the servo pin (67) in order to
retain the servo cushion springs (68) and the servo
piston (69).
3. Assemble the new seals (71, 72) onto the servo pis-
ton (69) and the servo cover (73).
4. Assemble the servo piston assembly (67-70) into the
servo cover (73). Lubricate the piston seals with
transmission fluid in order to aid in assembly.

A103A245

OIL FEED PIPES ASSEMBLE

Tools Required
J 36850 Transjelt
1. Inspect the oil feed pipes (83) for plugged passages,
bent pipes, or cracks.
2. Inspect the oil feed pipe seal rings (82) in order to
verify the proper location of the seal rings (82).
Important: The oil feed pipe seals are glued into place
during initial assembly. If you must replace a seal ring,
be sure to thoroughly clean any residual glue from the oil
feed pipes.
3. Replace the seal rings (82) only if they are cut,
swelled or damaged.
4. Clean and dry the oil feed pipes.

A103A246

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5A -- 266 4T40-E AUTOMATIC TRANSAXLE
5. Install new oil feed pipe seal rings (82) if necessary.
6. Retain any newly installed oil feed pipe seal rings (82)
with J 36850 or equivalent.
7. Install the oil feed pipe assembly (83) onto the trans-
mission case (51).
8. Install the four oil feed pipe bolts (81). Hand start and
then tighten the bolts to 12 NSm (9 lb-ft).

A103A080

FILTER ASSEMBLY AND SEAL

INSTALL
Important: In order to prevent damage to the case bore
and seal, tap gently and evenly of the seal (84).
1. Install a new oil filter seal (84) into the transmission
case (51). Use a large socket in order to tap on the
seal.

A103A247

2. Install a new filter assembly (85) into the filter seal

(81). If necessary, twist the filter slightly during
installation.

A103A248

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 267

OIL LEVEL CONTROL VALVE

INSTALL
Install the oil level control valve into the transmission
case (51). Push straight down on the center of the oil
level control valve in order to prevent damage to the
case bore.

A103A249

OIL PAN AND GASKET INSTALL

1. Inspect the oil pan (88) for cracks, dents or damage
to the gasket sealing surface.
2. Inspect the gasket (87) for cuts or other damage. The
bottom pan gasket is reusable if not damaged.
3. Clean and dry the bottom pan and gasket.

A103A250

4. Install the gasket and bottom pan onto the transmis-

sion case.

A103A078

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5A -- 268 4T40-E AUTOMATIC TRANSAXLE
5. Install the twelve bottom pan bolts (81).

A103A251

6. Hand start and then tighten the bottom pan bolts to

12 NSm (9 lb-ft).

A103A252

TORQUE CONVERTER
INSTALLATION
Tools Required
J 21366 Torque Converter Holding Strap
1. Install a new turbine shaft O-ring (41) on the end of
the turbine shaft.
2. Install the torque converter onto the transmission.
3. Install the J 21366.
4. Remove the transmission from the holding fixture.

A103A074

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 4T40-E AUTOMATIC TRANSAXLE 5A -- 269

GENERAL DESCRIPTION D Firm - a noticeably quick apply of a clutch or band

that is considered normal with a medium to heavy
AND SYSTEM OPERATION throttle. Should not be confused with “HARSH” or
“ROUGH.”
TRANSAXLE DEFINITIONS AND D Flare - a quick increase in engine RPM along with a
momentary loss of torque. This most generally oc-
ABBREVIATIONS curs during a shift. Also defined as “SLIPPING.”
The following definitions and abbreviations are provided
D Harsh (Rough) - a more noticeable apply of a clutch
to establish a common language for describing trans-
or band as compared with “FIRM.” This condition is
axle-related conditions. These terms are used in the
considered undesirable at any throttle position.
transaxle section of this manual.
D Hunting - a repeating quick series of upshifts and
Throttle Positions downshifts that causes a noticeable change in engine
D Minimum Throttle - the least amount of throttle RPM. An example could be described as a 4-3-4 shift
opening required for an upshift. pattern. Also defined as “BUSYNESS.”
D Light Throttle - approximately 1/4 of accelerator D Initial Feel - a distinct firmer feel at the start of a shift
pedal travel (25% throttle position). as compared to the finish of the shift.
D Medium Throttle - approximately 1/2 of accelerator D Late - a shift that occurs when the engine is at a high-
pedal travel (50% throttle position). er than normal RPM for a given amount of throttle.
D Heavy Throttle - approximately 3/4 of accelerator D Shudder - a repeating jerking condition similar to
pedal travel (75) throttle position). “CHUGGLE” but more severe and rapid. This condi-
tion may be most noticeable during certain ranges of
D Wide Open Throttle (WOT) - full travel of the accel-
car speed.
erator pedal (100% throttle position).
D Slipping - a noticeable increase in engine RPM with-
D Full Throttle Detent Downshift - a quick apply of
out a car speed increase. A slip usually occurs during
the accelerator pedal to its full travel, forcing a down-
or after initial clutch or band apply.
shift.
D Soft - a slow, almost unnoticeable clutch or band ap-
D Zero Throttle Coastdown - a full release of the ac-
ply with very little shift feel.
celerator pedal while the car is in motion and in drive
range. D Surge - a repeating engine related condition of accel-
eration and deceleration that is less intense than
D Engine Braking - a condition where the engine is
“CHUGGLE.”
used to slow the car by manually downshifting during
a zero throttle coastdown. D Tie-Up - a condition where two opposing clutches
and/or bands are attempting to apply at the same
Shift Conditions time causing the engine to labor with a noticeable
D Bump - a sudden and forceful apply of a clutch or loss of engine RPM.
band.
Noise Conditions
D Chuggle - a bucking or jerking that may be most no-
D Drive Link Noise - a whine or growl that increases
ticeable when the converter clutch is engaged; similar
or fades with engine RPM. Noise is not noticeable un-
to the feel of towing a trailer.
der light throttle acceleration or in “DRIVE” or “RE-
D Delayed - a condition where a shift is expected but VERSE” with the car stationary.
does not occur for a period of time. Samples of this
D Final Drive Noise - a hum related to car speed and is
could be described as clutch or band engagement
most noticeable under light throttle acceleration or
that does not occur as quickly as expected during a zero throttle coast down.
part throttle or wide open throttle apply of the acceler-
ator or, when manually downshifting to a lower range. D Planetary Gear Noise - a whine, most noticeable in
Also defined as “LATE” or “EXTENDED.” first gear and reverse that is related to vehicle speed.
A gear noise condition may become less noticeable
D Double Bump (Double Feel) - two sudden and or go away after an upshift.
forceful applies of a clutch or band.
D Pump Noise - a high pitch whine that increases
D Early - a condition where the shift occurs before the intensity with engine RPM. This condition may also
car has reached proper speed. Tends to labor the en-
be noticeable in ALL operating ranges.
gine after the upshift.
D Torque Converter - a whine usually noticed when
D End Bump - a firmer feel at the end of a shift as
a vehicle is stopped and transaxle is in “DRIVE” or
compared to the feel at the start of the shift. Also de-
“REVERSE.” The noise will increase with engine
fined as “END FEEL” or “SLIP BUMP.”
RPM. See Torque Converter Evaluation for further in-
formation.

DAEWOO J-100 BL2 / BL3

5A -- 270 4T40-E AUTOMATIC TRANSAXLE

Abbreviations D N - Neutral allows the engine to be started and oper-

D TCM - Transmission Control Module ated while driving the vehicle. If necessary, this posi-
tion may be selected if the engine must be restarted
D TCC Sol. Valve - Torque Converter Clutch Solenoid with the vehicle moving.
Valve
D D - Overdrive Range is used for all normal driving
D TP Sensor - Throttle Position Sensor conditions. It provides four gear ratios plus converter
D ECT Sensor - Engine Coolant Temperature Sensor clutch operation. Downshifts are available for safe
D A/T OSS Sensor - Automatic Transmission Output passing by depressing the accelerator.
(Shaft) Speed Sensor D 3 - Drive Range position is used for city traffic, hilly
D A/T ISS - Automatic Transmission Input Shaft Speed terrain and trailer towing. It provides three gear ratios
Sensor and prevents the transaxle from operating in fourth
D NC - Normally Closed gear. Again, downshifts are available by depressing
the accelerator.
D NO - Normally Open
D 2 - Manual Second Range only provides two gear ra-
D PCS - Pressure Control Solenoid tios (under most operating conditions). It is used to
D TFP Val Position Sw. - Transmission Fluid Pressure provide acceleration and engine braking. This range
Valve Position Switch may be selected at any vehicle speed, but the trans-
D PWM - Pulse Width Modulated axle will not downshift into Second gear until vehicle
D WOT - Wide Open Throttle speed drops below approximately 100 km/h
(62 mph).
D RPM - Revolutions Per Minute
D 1 - Manual Lo Range is used to provide maximum en-
D ECM - Electronic Control Module gine braking. This range may also be selected at any
D PM - Permanent Magnet vehicle speed, but the transaxle will not downshift into
D A/C - Air Conditioning First gear until vehicle speed drops below approxi-
D MAP - Manifold Absolute Pressure mately 60 km/h (37 mph).
D TFT - Transmission Fluid Temperature (Sensor)
TRANSAXLE COMPONENT AND
D AC - Alternating Current
SYSTEM DESCRIPTION
D DC - Direct Current
The 4T40-E transaxle consists primarily of the following
D CKT - Circuit components.
D DTC - Diagnostic Trouble Code
Mechanical
D DVM - Digital Volt Meter
D Torque converter with TCC
D OBD - On Board Diagnostics
D Drive link assembly
D DLC - Diagnostic Link Connector
D Five multiple disk clutch assemblies: 2nd, Reverse,
D EGR - Exhaust Gas Recirculation Direct, Coast and Forward
D Two friction bands: Intermediate/4th band and Lo/Re-
TRANSAXLE GENERAL verse band
DESCRIPTION D Three one-way clutches: two roller clutches (2nd and
The 4T40-3 is a fully automatic, electronically-controlled Lo) and one sprag clutch
front wheel drive transaxle. It provides four forward gear D Two planetary gear sets: Input and Reaction
ranges including overdrive and one reverse gear range. D Final drive and differential assembly
Shift points are controlled by the TCM through two shift D One control valve assembly
solenoids. Oil pressure is supplied by a vane-type pump
and is regulated electronically by the TCM through the D One vane-type oil pump
Pressure Control Solenoid (PC Sol. Valve). Electronic
The transaxle can be operated in any one of the follow- D Pressure Control Solenoid Valve (PC Sol. Valve)
ing seven modes. D Two shift solenoids: 1-2 and 2-3
D P - Park position prevents the vehicle from rolling ei- D TCC solenoid valve
ther forward or backward. (For safety reasons,
the parking should be used in addition to the park D Two speed sensors; A/T ISS and A/T OSS
position.) D Fluid temperature sensor
D R - Reverse allows the vehicle to be operated in a D Automatic Transmission Fluid Pressure (TFP) Manual
rearward direction. Valve Position Switch
D Wiring harness assembly

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 271

A103A315

DAEWOO J-100 BL2 / BL3

5A -- 272 4T40-E AUTOMATIC TRANSAXLE

RANGE REFERENCE CHART

4T40-E GEAR RATIOS
FIRST 2.96
SECOND 1.62
THIRD 1.00
FOURTH 0.68
REVERSE 2.14

S
S S S
S S
S
S

S S

1Ć2 2Ć 3 2ND INT./4TH REVERSE COAST INPUT DIRECT FORĆ LO/REV. LO

RANGE GEAR SHIFT SHIFT CL2U
ND RO
T
CH LLER WARD ROLLER
SOL SOL CLUTCH BAND CLUTCH CLUTCH SPRAG CLUTCH CLUTCH BAND CLUTCH
PARK N ON OFF APPLIED
REV R ON OFF APPLIED APPLIED
NEU N ON OFF APPLIED
1st ON OFF HOLDING APPLIED HOLDING
OVER-
2nd OFF OFF APPLIED HOLDING HOLDING APPLIED
RUNNING
D OVER- OVER-
3rd OFF ON APPLIED* HOLDING APPLIED APPLIED
RUNNING RUNNING
OVER- OVER-
4th ON ON APPLIED* APPLIED APPLIED APPLIED APPLIED*
RUNNING RUNNING
1st ON OFF APPLIED HOLDING APPLIED HOLDING
OVER-
2nd OFF OFF APPLIED HOLDING APPLIED HOLDING APPLIED
3 RUNNING
OVER- OVER-
3rd OFF ON APPLIED* APPLIED HOLDING APPLIED APPLIED
RUNNING RUNNING
1st ON OFF APPLIED HOLDING APPLIED HOLDING
OVER-
2nd OFF OFF APPLIED HOLDING APPLIED APPLIED HOLDING APPLIED
2 RUNNING
OVER- OVER-
3rd** OFF ON APPLIED* APPLIED HOLDING APPLIED APPLIED
RUNNING RUNNING
1st ON OFF APPLIED HOLDING APPLIED APPLIED HOLDING
1 OVER-
2nd*** OFF OFF APPLIED HOLDING APPLIED APPLIED HOLDING APPLIED
RUNNING

ON = SOLENOID ENERGIZED
OFF = SOLENOID DE-ENERGIZED
* = APPLIED WITH NO LOAD.
** = MANUAL SECOND - THIRD GEAR IS ONLY AVAILABLE ABOVE APPROXIMATELY 100 km/h (62 mph).
*** = MANUAL FIRST - SECOND GEAR IS ONLY AVAILABLE ABOVE APPROXIMATELY 60 km/h (37 mph).
NOTE: MANUAL FIRST - THIRD GEAR IS ALSO POSSIBLE AT HIGH VEHICLE SPEED AS A SAFETY FEATURE. A103A316

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 273

AUTOMATIC TRANSMISSION
OUTPUT (SHAFT) SPEED SENSOR
(A/T OSS)
The vehicle A/T OSS is a magnetic inductive pickup that
relays information relative to vehicle speed to the TCM.
Vehicle speed information is used by the TCM to control
shift timing, line pressure, and TCC apply and release.

A103A333

The input speed sensor mounts on the transaxle case

under the channel plate and next to the drive sprocket.
An air gap of 0.26-2.90 mm (0.010-0.114 inch) is main-
tained between the sensor and the teeth on the drive
sprocket. The sensor consists of a permanent magnet
surrounded by a coil of wire. As the drive sprocket is
driven by the turbine shaft, an AC signal is induced in the
A103A317 input speed sensor. Higher vehicle speeds induce a high-
er frequency andvoltage measurement at the sensor.
The output speed sensor mounts in the case at the Sensor resistance should measure between 625-725
speed sensor rotor which is pressed onto the differential. ohms at 20_C (68_F). Output voltage will vary with ve-
An air gap of 0.27-1.57 mm (0.011-0.062 inch) is main- hicle speed from a minimum of 0.5 volts AC at 550 RPM
tained between the sensor and the teeth on the speed to 200 volts at 7000 RPM.
sensor rotor. The sensor consists of a permanent mag-
net surrounded by a coil of wire. As the differential SHIFT SOLENOIDS: 1-2 AND 2-3
rotates, an AC signal is induced in the output speed The shift solenoids are two identical, normally open
sensor. Higher vehicle speeds induce a higher frequency electronic exhaust valves that control upshifts and
and voltage measurement at the sensor. downshifts in all forward gear ranges. These shift sole-
Sensor resistance should measure between 1500-1750 noids work together in a combination of ON and OFF se-
ohms at 20_C (68_F). Output voltage will vary with ve- quences to control the positions of the 1-2, 2-3 and 3-4
hicle speed from a minimum of 0.5 volts AC at 25 RPM shift valve trains. The TCM monitors numerous inputs to
to 200 volts at 1728 RPM. determine the appropriate solenoid state combination
and transmission gear for the vehicle operating condi-
tions.
AUTOMATIC TRANSMISSION
INPUT (SHAFT) SPEED SENSOR Gear
Solenoid Solenoid
(A/T ISS) 1-2 2-3
Park, Reverse, Neutral* ON OFF
The A/T ISS is a magnetic inductive pickup that relays
information relative to transaxle input speed to the TCM. First ON OFF
The TCM uses transaxle input speed information to con- Second OFF OFF
trol line pressure, TCC apply and release and transaxle Third OFF ON
shift patterns. This information is also used to calculate
the appropriate operating gear ratios and TCC slippage. Fourth ON ON
*The solenoid states are normally on (1-2) and off
(2-3) in P, R, N. However, these may change based
on vehicle speed and throttle position.

DAEWOO J-100 BL2 / BL3

5A -- 274 4T40-E AUTOMATIC TRANSAXLE

A103A334 A103A318

The TCM energizes the shift solenoids by providing a The TCM controls the PC sol. valve on a positive duty
ground to the solenoid’s electrical circuit. This sends cycle at a fixed frequency of 614 Hz (cycles per second).
current through the coil winding of the solenoid, thereby Duty cycle is defined as the percent of time current is
creating a magnetic field. The magnetic field repels the flowing through the solenoid coil during each cycle. A
plunger inside the solenoid which seats the solenoid me- higher duty cycle provides a greater current flow through
tering ball against the fluid inlet port. This action pre- the solenoid. The high (positive) side of the PC sol.
vents the exhaust of fluid through the solenoid and valve electrical circuit at the TCM controls the PC sol.
provides an increase in fluid pressure at the end of the valve operation. The TCM provides a ground path for
shift valves. This fluid pressure initiates an upshift by the circuit, monitors average current and continuously
moving the shift valves (refer to the oil flow diagrams for varies the PC sol. valve duty cycle to maintain the cor-
a complete description of the hydraulic control of the rect average current flowing through the PC sol. valve.
shift valves for each gear range).
Shift solenoids resistance should measure between Duty Cycle Current Line Pressure
19-24 ohms when measured at 20_C (68_F) and be- +5% 0.02 amps Maximum
tween 24-31 ohms when measured at 88_C (190_F). +40% 1.1 amps Minimum
The shift solenoids should energize when the voltage
is greater than 7.5 volts. The shift solenoids should Pressure control solenoid valve resistance should mea-
de-energize when the voltage is less than one volt. sure between 3.5 and 4.6 ohms when measured
at 20_C (68_F).
Transmission Adapt Function
PRESSURE CONTROL SOLENOID The 4T40-E uses a line pressure control system which
VALVE (PC SOL. VALVE) has the ability to continuously adapt the system’s line
pressure (increase as needed) to compensate for nor-
The pressure control solenoid valve (PC sol. valve) is a
mal wear of clutch fiber plates, seals, springs, etc. this
precision electronic pressure regulator that controls
“learning” feature is similar to what is used for fuel
transaxle line pressure based on current flow through its
control (integrator/block learn) and throttle position (idle
coil windings. As current flow is increased the magnetic
learn). The TCM maintains several adapt parameters for
field produced by the coil moves the solenoid’s plunger
the transaxle:
further away from the exhaust port. Opening the ex-
haust port decreases the output fluid pressure regulated D Upshift Adapt - The TCM monitors the TIS sensor
by the PC sol. valve, which ultimately decreases line and VSS during commanded shifts to determine if a
pressure. The TCM controls the PC sol. valve based on shift is occurring too fast (harsh) or too slow (soft) and
various inputs including throttle position, fluid tempera- adjusts the transaxle pressure control solenoid signal
ture, MAP sensor and gear state. to maintain a set shift feel.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 275
TCM then ramps the duty cycle up to approximately
93% to achieve full TCC apply pressure. The rate at
which the TCM increases the duty cycle controls the
TCC apply. Similarly, the TCM also ramps down the
TCC solenoid duty cycle to control TCC release.
There are some operating conditions that prevent or en-
able TCC apply under various conditions (refer to the
temperature sensor description). Also, if the TCM re-
ceives a high voltage signal from the brake switch, sig-
nalling that the brake pedal is depressed, the TCM
immediately releases the TCC.
Important: Duty cycles given are for example only. Ac-
tual duty cycles will vary depending on vehicle applica-
tion and vehicle operating conditions.

A103A336

TORQUE CONVERTER CLUTCH

SOLENOID VALVE (TCC SOL. VALVE)
The TCC solenoid valve is a normally closed, pulse
width modulated (PWM) solenoid used to control the ap-
ply and release of the converter clutch. The TCM oper-
ates the solenoid with a negative duty cycle at a fixed
frequency of 42 Hz to control the rate of TCC apply/re-
lease. The solenoid’s ability to “ramp” the TCC apply
and release pressures results in a smoother TCC opera-
tion.

A103A337

TCC solenoid valve resistance should measure between

10.4 and 10.8 ohms when measured at 20_C (68_F).
The resistance should measure approximately 16 ohms
at 150_C (300_F).

AUTOMATIC TRANSMISSION
FLUID PRESSURE MANUAL
VALVE POSITION SWITCH
(TFP VAL. POSITION SW.)
The pressure switch assembly (TFP val. position sw.) is
attached to the valve body and contains six fluid pres-
sure switches and the transaxle temperature sensor (re-
fer to the separate description of the temperature
A103A335
sensor). Five of the fluid pressure switches (PRND4,
DRIVE, LO, D21, REV) are normally open and are used
When vehicle operating conditions are appropriate to to indicate the position of the manual valve. The TCM
apply the TCC the TCM immediately increases the duty uses this information to control line pressure, TCC apply
cycle to approximately 68% (see point A on graph). The and release and shift solenoid operation.

DAEWOO J-100 BL2 / BL3

5A -- 276 4T40-E AUTOMATIC TRANSAXLE

Range Fluid* Circuit+

Indicator REV PRND4 DR D21 LO A B C
Park/Neutral 0 1 0 0 0 1 0 0
Reverse 1 1 0 0 0 1 0 1
Overdrive 0 1 1 0 0 1 1 0
Manual Third 0 0 1 0 0 0 1 0
Manual Second 0 0 1 1 0 0 1 1
Manual First 0 0 1 1 1 1 1 1
*:1 =Pressurized
0 =Exhausted
Exhausted
+: 1 =Grounded(resistance <50 ohms, 0 volts)
0 =Open(Resistance >50kohms, 12 volts)

Important: Resistance should be measured with the

engine running. When the transaxle pass thru connector
is disconnected from the vehicle harness and the engine
A105A319 is running, multiple diagnostic codes will be set. Be sure
to clear these codes when finished with this procedure.
The RELEASE pressure switch is a normally closed
pressure switch. This switch is used as a diagnostic tool TRANSMISSION FLUID
to confirm that the TCC is actually OFF when it has been
commanded OFF by the TCM.
TEMPERATURE (TFT) SENSOR
The TFT sensor is a negative temperature coefficient
Each fluid pressure switch produces either an open or
thermistor (temperature sensitive resistor) that provides
ground to the TCM depending on the presence of fluid
information to the TCM regarding transmission fluid
pressure at the switches. The sequence of open and
temperature. The temperature sensor is integrated in
closed switches produces a combination of voltage
the TFP val. position sw. which is volted to the valve
readings that are monitored by the TCM (see chart and
body. The sensor monitors pressurized main line pres-
switch logic diagram).
sure from the inside of the valve body to determine the
operating temperature of the transaxle fluid. The sensor,
similar to each of the TFP val. position sw., uses an O-
ring seal to maintain fluid pressure in the valve body.

A103A338

The TCM measures TFP val. position sw. signal voltage

from each pin to ground and compares the voltage to a A103A339
TFP val position sw. combination chart stored in the
TCM memory. If the TCM does not recognize the switch
The internal electrical resistance of the sensor varies in
sequence a diagnostic code will be set as a result. A
relation to the operating temperature of the transmission
diagnostic code may also be set if the TFP val. position
fluid (see chart).
sw. switch sequence indicates a gear range selection
that conflicts with other sensory inputs to the TCM.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 277

TRANSMISSION ELECTRICAL
CONNECTOR
The transmission electrical connector is a very impor-
tant part of the transmission operating system. Any in-
terference with the electrical connection can cause the
Sensor Resistance (K-Ohms)

transmission to set Diagnostic Trouble Codes (DTCs)

and/or affect proper operation.
The following items can affect the electrical connection:
D Bent pins in the connector from rough handling during
connection and disconnection.
D Wires backing away from the pins or coming un-
crimped(in either internal or external wiring harness).
D Dirt contamination entering the connector when
disconnected.
D Pins in the internal wiring connector backing out of
the connector or pushed out during reconnection.
A103A340
D Excessive transmission fluid leaking into the connec-
tor, wicking up into the external wiring harness, and
The TCM sends a 5 volt reference signal to the temper-
degrading the wire insulation.
ature sensor and measures the voltage drop in the elec-
trical circuit. A lower fluid temperature creates a higher D Water/moisture intrusion in the connector.
resistance in the temperature sensor, thereby measur- D Low pin retention in the external connector from ex-
ing a higher voltage signal. cessive connection and disconnection of the wiring
The TCM measures this voltage as another input to help connector assembly.
control line pressure, shift schedules and TCC apply. D Pin corrosion from contamination.
When transaxle fluid temperature reaches 140_C D Broken/cracked connector assembly.
(284_F) the TCM enters “hot mode.” Above this temper-
Points to remember when working with the transmission
ature the TCM modifies transmission shift schedules
wiring connector assembly:
and TCC apply in an attempt to reduce fluid temperature
by reducing transmission heat generation. During hot D To remove the connector, squeeze the two tabs to-
mode the TCM applies the TCC at all times in third and wards each other and pull straight up (refer to the il-
fourth gears. Also, the TCM performs the 2-3 and 3-4 lustration).
shifts earlier to help reduce fluid heat generation. Hot
mode may not be available on some applications.

Transmission Sensor - Temperature To

Resistance To Voltage (approximate)
_C R low (ohms) R high (ohms)
0 7987 10859
10 4934 6407
20 3106 3923
30 1991 2483
40 1307 1611
50 878 1067
60 605 728
70 425 507
80 304 359
90 221 259
100 163 190

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5A -- 278 4T40-E AUTOMATIC TRANSAXLE

TRANSMISSION CONTROL MODULE

(TCM)
The transmission control module (TCM) is an electronic
device which monitors inputs to control various trans-
mission functions including shift quality and transmis-
sion diagnostics. The TCM receives input information
from sensors, switches, and components to process
for use within its’ control program. Based on this input
information, the TCM controls various transmission
output functions and devices.

DATA LINK CONNECTOR (DLC)

The data link connector (DLC) is a multiple cavity con-
nector. The DLC provides the means to access serial
data from the TCM to aid in powertrain diagnosis. The
DLC allows the technician to use a scan tool to monitor
various systems and display diagnostic trouble codes
(DTCs). The DLC connector is located within the driver’s
compartment, directly below the steering column.

A103A320

A103A321
D Carefully limit twisting or wiggling the connector dur-
ing removal. Bent pins can occur.
D DO NOT pry the connector off with a screwdriver or
other tool. TCM INPUTS THAT AFFECT THE
D To reinstall the external wiring connector, first orient 4T40-E TRANSMISSION
the pins by lining up the arrows on each half of the
connector. Push the connector straight down into the
Throttle Position Sensor
transmission without twisting or angling the mating D Provides throttle position data to the TCM for
parts. determining shift patterns and TCC apply/release.
D The connector should click into place with a positive D An incorrect throttle position sensor input could cause
feel and/or noise. erratic or shift pattern, poor shift quality or TCC
function.
D Whenever the transmission external wiring connector
is disconnected from the internal harness and the en-
gine is operating DTC(s) will set. Clear these DTC(s)
after reconnecting the external connector.

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 279

Automatic Transmission Output (Shaft) Brake Switch

Speed Sensor D Provides brake apply information to the TCM for con-
D Provides vehicle speed data to the TCM for determin- trolling TCC apply and release.
ing shift patterns, TCC apply/release, and gear ratio D An incorrect TCC brake switch input could cause an
calculations. incorrect TCC apply or release.
D An incorrect A/T OSS input could cause erratic or Automatic Transmission Fluid Pressure
shift pattern, poor shift quality or TCC function.
Manual Valve Position Switch (TFP Val.
Automatic Transmission Input (Shaft) Position Sw.)
Speed Sensor D Provides transaxle shift linkage position information
D Provides transaxle input speed data to the TCM for to the TCM for determining transaxle range and shift
controlling line pressure, shift patterns, TCC apply patterns.
and release and calculating gear ratio. D An incorrect TFP val. position sw. input could cause
Engine Coolant Temperature Sensor incorrect shift points, poor shift quality, incorrect or in-
hibited TCC apply, incorrect line pressure, or erratic
D Provides coolant temperature data to the TCM for de-
manual downshifts.
termining initial TCC engagement.
D An incorrect engine coolant temperature sensor input Transmission Fluid Temperature TFT
could cause an incorrect initial TCC apply. Sensor
Cruise Control D Provides transaxle fluid temperature information to
the TCM for determining alternate shift patterns and
D When engaged, the TCM alters the transaxle shift TCC apply during high temperature conditions (hot
pattern to reduce the number of 3-4 upshifts and 4-3
mode operation).
downshifts. The TCM also alters TCC apply and re-
lease. D An incorrect transaxle temperature sensor input
could cause altered shift patterns, poor shift quality
Engine Speed and incorrect TCC apply.
D The ignition module provides engine speed data to
Manifold Absolute Pressure Sensor
the TCM.
D Measures intake manifold pressure which results
D The TCM uses engine speed information for con- from changes in engine load and speed. The TCM
trolling wide open throttle shifts and the TCC PWM monitors this information to adjust line pressure and
solenoid duty cycle. shift patterns.
D An incorrect MAP sensor input could cause altered
shift patterns, shift feel and TCC apply.

DAEWOO J-100 BL2 / BL3

5A -- 280 4T40-E AUTOMATIC TRANSAXLE

PARK (ENGINE RUNNING)

A103A322

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 281
When the gear selector lever is in the park (P) position 1-2 Shift Valve: 1-2 signal fluid pressure holds the valve
and the engine is running, fluid is drawn into the oil pump in the downshifted position against spring force. Lo/PRN
and line pressure is directed to the pressure regulator fluid is routed through the 1-2 shift valve and into the lo
valve. band fluid circuit.
Pressure Regulation Lo and Reverse Servo: Lo band fluid is routed to the
inner area of the servo piston. Lo band fluid pressure
Pressure Regulator Valve: Regulates pump output
moves the servo piston and pin assembly against spring
(line pressure) in response to torque signal fluid pres-
force to apply the lo/reverse band.
sure acting on the boost valve, spring force, and line
pressure acting on the end of the valve. Line pressure is 2-3 Shift Solenoid: The normally open 2-3 shift sole-
directed to the manual valve, both accumulator valves, noid is OFF and 2-3 signal fluid is exhausted through the
torque signal regulator valve, TCC regulated apply solenoid.
valve, the temperature sensor in the TFP and the actua- 2-3 Shift Valve: Spring force holds the 2-3 shift valve in
tor feed limit valve. Also, line pressure feeds the con- the downshifted position.
verter feed fluid circuit through the pressure regulator 3-4 Shift Valve: 1-2 signal fluid pressure holds the 3-4
valve. shift valve against spring force in the first and fourth gear
Actuator Feed Limit (AFL) Valve: Line pressure is position.
routed through the valve and into the actuator feed fluid Lube 2: The lube 2 fluid circuit is fed by line pressure at
circuit. The valve limits actuator feed fluid pressure to a the pressure regulator valve. Lube 2 fluid is routed
maximum pressure. Actuator feed fluid is routed to the through the oil feed pipes and into the forward clutch
pressure control solenoid, each of the shift valves, and support. Lube 2 fluid provides lubrication in the rear of
also feeds the 1-2 signal and 2-3 signal fluid circuits. the transaxle.
Pressure Control Solenoid (PCS): Controlled by the
Shift Accumulation
TCM, the PCS regulates filtered actuator feed fluid pres-
sure acting on the end of the torque signal regulating 1-2/3-4 and 2-3 Accumulator Valves: Line pressure is
valve. regulated into accumulator fluid pressure. This regula-
tion is basically controlled by torque signal fluid pressure
Torque Signal Regulating Valve: Regulates line pres-
acting on the end of the valve.
sure into the torque signal fluid circuit. This regulation is
controlled by filtered actuator feed fluid pressure from 1-2, 2-3 and 3-4 Accumulator Assemblies: Accumula-
the PCS. Torque signal fluid pressure is routed to the ac- tor fluid is routed to each of the accumulator assemblies
cumulator valves and the boost valve to control shift in preparation for upshifts. The fluid routed to the 1-2
feel. and 3-4 accumulators is orificed by the #4 and #7 check-
balls. The 2-3 accumulator fluid circuit is orificed by
Lo/Reverse Band Applies checkball #6.
Manual Valve: Mechanically controlled by the gear se-
Torque Converter/Cooler and Lube
lector lever, the manual valve is in the park (P) position
and directs line pressure into the PRND4 and PRN fluid Circuits
circuits. Refer to reverse (R) range for a complete description of
TFP: PRND4 fluid is routed to the PRND4 fluid pressure these circuits.
switch in the TFP and the TFP signals the TCM that the Important: Actuator feed fluid continues to feed the 2-3
transaxle is in the park (P) position. Also, line pressure is signal fluid circuit through orifice #6. However, the ex-
routed to the temperature sensor in the TFP. haust port through 2-3 shift solenoid is larger than orifice
1-2 Shift Solenoid: Energized by the TCM, the normal- #6 to prevent a pressure increase in the 2-3 signal fluid
ly open 1-2 shift solenoid is ON and blocks 1-2 signal circuit.
fluid from exhausting. 1-2 signal fluid pressure acts on
the 1-2 and 3-4 shift valves.

DAEWOO J-100 BL2 / BL3

5A -- 282 4T40-E AUTOMATIC TRANSAXLE

REVERSE

A103A323

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 283
When the gear selector lever is moved to the reverse (R) TCC Feed Limit Valve: Converter feed fluid is routed
position (from the park position), the following changes through the valve and into the TCC feed limit fluid circuit.
occur in the transaxle’s hydraulic and electrical systems. The TCC feed limit valve limits the maximum fluid
pressure in the TCC feed limit fluid circuit and the torque
Pressure Regulation
converter.
Manual Valve: With the manual valve in the reverse
TCC Regulated Apply Valve: Spring force holds the
position, line pressure is directed into the reverse fluid
valve in the release position, thereby blocking line
circuit, in addition to the PRND4 and PRN fluid circuits
pressure.
as in park.
TCC Control Valve: Spring force holds the valve in the
Pressure Regulator and Boost Valves: Reverse fluid
release position and TCC feed limit fluid is routed into
is routed to the boost valve and assists torque signal fluid
the release fluid circuit. Also, fluid returning from the
pressure. The addition of reverse fluid pressure in-
converter in the apply fluid circuit is routed through the
creases the operating range of line pressure in reverse.
valve and into the cooler fluid circuit.
TFP: Reverse fluid is routed through the 1-2 shift valve
Torque Converter: Release fluid pressure is routed to
and to the TFP. The TFP signals the TCM that the
the torque converter to keep the TCC released. Fluid
transaxle is in reverse.
leaves the converter in the apply fluid circuit.
Reverse Clutch Applies Cooler and Lube
Reverse Clutch: Reverse clutch fluid pressure applies
Lube 1: Cooler fluid is routed through the transaxle oil
the reverse clutch.
cooler located in the vehicle radiator and into the lube 1
Lo and Reverse Band Remains Applied fluid circuit. Lube 1 fluid is routed through the input shaft
1-2 Shift Solenoid: The TCM keeps the solenoid ener- to lubricate transaxle components in the front of the
gized in reverse and 1-2 signal fluid pressure acts on the transaxle.
1-2 shift valve. Lube 2: The lube 2 fluid circuit is fed by line pressure at
1-2 Shift Valve: 1-2 signal fluid pressure keeps the 1-2 the pressure regulator valve. Lube 2 fluid is routed
shift valve in the downshifted position. Lo/PRN fluid con- through the oil feed pipes and into the forward clutch
tinues to feed the lo band fluid circuit. support. Lube 2 fluid provides lubrication in the rear of
Lo and Reverse Servo: Reverse fluid is routed to the the transaxle.
outer area of the servo to increase the servo apply pres- Important: The explanation in each gear range is, for
sure in reverse. the most part, limited to what changes from the pre-
Torque Converter Clutch vious range. However, some component descriptions
are repeated for clarity and continuity. Also, refer to the
Pressure Regulator Valve: Line pressure is routed
appropriate service manual for specific application in-
through the PR valve and into the converter feed fluid
formation.
circuit. Converter feed fluid is routed to the TCC feed
limit valve.

DAEWOO J-100 BL2 / BL3

5A -- 284 4T40-E AUTOMATIC TRANSAXLE

NEUTRAL (ENGINE RUNNING)

A103A324

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 285
When the gear selector lever is moved from the reverse 1-2 Shift Valve: 1-2 signal fluid pressure keeps the 1-2
position to the neutral position, the following changes shift valve in the downshifted position. Lo/PRN fluid con-
occur to the hydraulic and electrical systems. tinues to feed the lo band fluid circuit.
Reverse Clutch Releases Lo and Reverse Servo: Reverse fluid exhausts from
the servo. However, lo band fluid pressure continues to
Manual Valve: The manual valve is moved to the
act on the inner area of the servo piston to keep the
neutral position and blocks line pressure from entering
band applied.
the reverse fluid circuit. The reverse fluid circuit is
opened to an exhaust at the manual valve. Important: In park, reverse and neutral, the shift sole-
Reverse Clutch: Reverse fluid exhausts from the re- noids are shown in the first gear state. This is the normal
verse clutch and the clutch releases, shifting the trans- operating state when the vehicle is stationary or at low
axle into neutral. vehicle speeds. However, the TCM will change the shift
solenoid states depending on vehicle speed. For exam-
Boost Valve: Reverse fluid exhausts from the boost
ple, if neutral range is selected when the vehicle is oper-
valve and line pressure regulation returns to the normal
ating in second gear, the shift solenoids will remain in a
operating range.
second gear state. But with the manual valve in neutral,
TFP: Reverse fluid pressure exhausts from the TFP, line pressure is blocked, drive fluid exhausts and the
thereby signalling the TCM that the transaxle is in transmission will shift into neutral.
neutral (N) or park (P).
Lo and Reverse Band Remains Applied
1-2 Shift Solenoid: As in park and reverse, the sole-
noid is energized and 1-2 signal fluid pressure acts on
the 1-2 shift valve.

DAEWOO J-100 BL2 / BL3

5A -- 286 4T40-E AUTOMATIC TRANSAXLE

OVERDRIVE RANGE - FIRST GEAR

A103A325

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 287
When the gear selector lever is moved to the overdrive Forward Clutch Applies
(D) position from the neutral (N) position, the following Forward Clutch: Drive fluid is orificed into the forward
changes occur to shift the transaxle into overdrive range clutch fluid circuit. Forward clutch fluid pressure applies
- first gear. the forward clutch.
Manual Valve: In the overdrive position the manual 1-2 Shift Solenoid: In first gear 1-2 shift solenoid re-
valve routes line pressure into the drive fluid circuit. mains energized by the TCM and 1-2 signal fluid pres-
Also, the manual valve blocks line pressure from enter- sure acts on the 1-2 shift valve.
ing the PRN fluid circuit and opens the PRN fluid circuit
to exhaust. 1-2 Shift Valve: 1-2 signal fluid pressure keeps the 1-2
shift valve in the downshifted position against spring
Low and Reverse Band Releases force. Drive fluid is routed through the 1-2 shift valve.
Lo and Reverse Servo: Lo band fluid pressure ex- TFP: Drive fluid is routed to the TFP and the TFP sig-
hausts from the servo, thereby releasing the servo and nals the TCM that the transaxle is in the overdrive range.
the lo and reverse band.

DAEWOO J-100 BL2 / BL3

5A -- 288 4T40-E AUTOMATIC TRANSAXLE

OVERDRIVE RANGE - SECOND GEAR

A103A326

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 289
As vehicle speed increases and operating conditions be- against spring force and 1-2 accumulator feed fluid pres-
come appropriate, the TCM de-energizes shift 1-2 sole- sure. This action absorbs initial 2nd clutch fluid pressure
noid to shift the transaxle into second gear. The manual to cushion the second clutch apply. The movement of
valve remains in the overdrive (D) position and line pres- the 1-2 accumulator piston forces some accumulator
sure is routed into the drive and PRND4 fluid circuits. fluid out of the accumulator.
Second Clutch Applies 1-2 Accumulator Valve: 1-2 accumulator feed fluid
forced from the 1-2 accumulator unseats the #4 check-
1-2 Shift Solenoid: The normally open shift solenoid is
ball and is routed back to the 1-2 accumulator valve.
de-energized and 1-2 signal fluid exhausts through the
This pressure forces the 1-2 accumulator valve against
open solenoid.
spring force and torque signal fluid pressure to regulate
Important: Filtered actuator feed fluid continues to feed the exhaust of excess accumulator fluid. This regulation
the 1-2 signal fluid circuit through orifice #7. However, provides additional control for the second clutch apply.
the exhaust port through the solenoid is larger than ori- Figure 39 shows the exhaust of accumulator fluid during
fice #7 to prevent a pressure increase in the 1-2 signal the shift by the arrow directions in the accumulator fluid
fluid circuit. circuit.
1-2 Shift Valve: With 1-2 signal fluid pressure ex- TCC Control - Pulse Width Modulated (PWM)
hausted, spring force moves the valve into the upshifted Solenoid: Filtered 2-3 drive fluid is routed to the TCC
position and drive fluid is routed into the 2-3 drive fluid control solenoid. Under normal operating conditions the
circuit. Drive fluid also continues to flow through the TCC control solenoid is OFF in second gear and blocks
valve and to the TFP. filtered 2-3 drive fluid from entering the TCC signal fluid
circuit.
#2 Checkball (Second Clutch Apply): 2-3 drive fluid
seats the #2 checkball, forces 2-3 drive fluid through the Torque Converter Clutch: With the TCC control sole-
#3 orifice and feeds the 2nd clutch fluid circuit. The #3 noid OFF ,the converter clutch is released in second
and #4 orifices help control the apply feel of the second gear.
clutch. 2-3 Shift Solenoid: 2-3 shift solenoid remains OFF in
Second Clutch: 2nd clutch fluid pressure applies the second gear and 2-3 signal fluid exhausts through the
second clutch to shift the transaxle into second gear. normally open solenoid.
2-3 Shift Valve: Spring force keeps the 2-3 shift valve in
Shift Accumulation
the downshifted position. In this position the valve
1-2 Accumulator: 2nd clutch fluid is also routed to the blocks 2-3 drive fluid in preparation for the upshift to
1-2 accumulator piston. Second clutch fluid pressure, in third gear.
addition to 1-2 assist spring force, moves the piston

DAEWOO J-100 BL2 / BL3

5A -- 290 4T40-E AUTOMATIC TRANSAXLE

OVERDRIVE RANGE - THIRD GEAR

A103A327

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 291
As vehicle speed increases and operating conditions be- Shift Accumulation
come appropriate, the TCM energizes 2-3 shift solenoid 2-3 Accumulator: Direct clutch feed fluid is also routed
to shift the transaxle into third gear. The manual valve to the 2-3 accumulator piston. This fluid pressure moves
remains in the overdrive (D) position and line pressure the piston against spring force and 2-3 accumulator feed
continues to feed the drive and PRND4 fluid circuits. fluid pressure. This action absorbs initial direct clutch
Direct Clutch Applies fluid pressure to cushion the direct clutch apply. The
2-3 Shift Solenoid: The normally open shift solenoid is movement of the 2-3 accumulator piston forces some
energized by the TCM and blocks 2-3 signal fluid from accumulator fluid out of the accumulator.
exhausting. 2-3 signal fluid pressure is routed to both 2-3 Accumulator Valve: Excess 2-3 accumulator feed
the 1-2 and 2-3 shift valves. fluid unseats the #6 checkball and is routed back to the
2-3 Shift Valve: 2-3 signal fluid pressure moves the 2-3 accumulator valve. This fluid pressure moves the
valve against spring force to initiate the 2-3 upshift. 2-3 accumulator valve against spring force and torque sig-
drive fluid is routed through the valve and into the 3-4 nal fluid pressure to regulate the exhaust of excess ac-
drive fluid circuit. cumulator fluid. This regulation provides additional
control for the direct clutch apply. The overdrive range -
#5 Checkball (Direct Clutch Apply): 3-4 drive fluid 4-3 downshift illustration shows the exhaust of accumu-
pressure seats the #5 checkball and 3-4 drive fluid is lator fluid during the shift by the arrow directions in the
forced through the #26 orifice and into the direct clutch accumulator fluid circuit.
feed fluid circuit. The #26 orifice helps control the direct
clutch apply. Torque Converter Clutch: Under normal operating
conditions the TCC is released in third gear. However,
Direct Clutch: Direct clutch fluid pressure applies the TCC apply could vary depending on vehicle application
direct clutch and the transaxle shifts into third gear. and may be calibrated to apply in overdrive range - third
3-4 Shift Valve: 3-4 drive fluid is also routed to the 3-4 gear.
shift valve in preparation for a 3-4 upshift. TFP: Release fluid pressure routed to the TFP signals
the TCM that the TCC is released.

DAEWOO J-100 BL2 / BL3

5A -- 292 4T40-E AUTOMATIC TRANSAXLE

OVERDRIVE RANGE - FOURTH GEAR

A103A328

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 293
When operating conditions are appropriate, the TCM against spring force and torque signal fluid pressure to
energizes 1-2 shift solenoid to shift the transaxle into regulate the exhaust of excess accumulator fluid. This
fourth gear. In addition, the TCC is applied in fourth gear. regulation provides additional control for the inter-
The manual valve remains in the overdrive position and mediate/4th band apply. The manual third - third gear
line pressure continues to feed the Drive and PRND4 illustration shows the exhaust of accumulator fluid dur-
fluid circuits. ing the shift by the arrow directions in the accumu-
lator fluid circuit.
Intermediate and 4th Band Applied
1-2 Shift Solenoid: The normally open shift solenoid is Torque Converter Clutch Applied
energized by the TCM and blocks 1-2 signal fluid from TCC Control Solenoid: When conditions are appropri-
exhausting. 1-2 signal fluid pressure is routed to both ate, the TCM energizes the TCC control solenoid to initi-
the 1-2 and 3-4 shift valves. ate the TCC apply. The solenoid is pulse width
1-2 Shift Valve: 1-2 signal fluid pressure does not modulated (PWM) to provide a smooth TCC apply
affect the 1-2 shift valve. Spring force and 2-3 signal (refer to the electrical controls section for a detailed
fluid pressure keep the 1-2 shift valve in the upshifted description of the TCC control solenoid operation).
position. When energized, the solenoid modulates filtered 2-3
drive fluid into the TCC signal fluid circuit.
3-4 Shift Valve: 1-2 signal fluid pressure moves the
valve against spring force and into the fourth gear posi- TCC Regulated Apply Valve: TCC signal fluid pres-
tion. 3-4 drive fluid is routed into the 4th band fluid cir- sure modulates the valve against spring force and TCC
cuit. regulated apply fluid pressure. This action directs line
pressure into the TCC regulated apply fluid circuit in
Intermediate and 4th Servo: 4th band fluid pressure
relation to vehicle operating conditions.
acts on the outer area of the servo piston to move the
servo pin and apply the intermediate/4th band. TCC Control Valve: Modulated TCC signal fluid pres-
sure moves the valve against spring force in relation to
Shift Accumulation vehicle operating conditions. This action regulates TCC
3-4 Accumulator: 4th band fluid is also routed to the regulated apply fluid into the apply fluid circuit. At the
3-4 accumulator piston. 4th band fluid pressure moves same time, the release fluid circuit is opened to an
the piston against spring force and 3-4 accumulator feed orificed exhaust. In this position the valve directs TCC
fluid pressure. This action absorbs initial 4th band fluid feed limit fluid to feed the cooler fluid circuit.
pressure to cushion the intermediate/4th band apply. Torque Converter Clutch: Apply fluid is routed to the
The movement of the 3-4 accumulator piston forces torque converter at the same time release fluid exhausts
some accumulator fluid out of the accumulator. from the converter. Apply fluid pressure applies the
3-4 Accumulator Valve: 3-4 accumulator feed fluid TCC.
forced from the 3-4 accumulator unseats the #7 check- TFP: Release fluid also exhausts from the TFP and the
ball and is routed back to the 3-4 accumulator valve. TFP signals the TCM that the TCC is released.
This pressure forces the 1-2/3-4 accumulator valve

DAEWOO J-100 BL2 / BL3

5A -- 294 4T40-E AUTOMATIC TRANSAXLE

OVERDRIVE RANGE - 4-3 DOWNSHIFT

A103A329

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 295
When the transaxle is operating in overdrive range - Intermediate/4th Servo: 4th band fluid exhausts from
fourth gear, a forced 4-3 downshift will occur if there is the servo and spring force moves the servo to the re-
a significant increase in throttle position. At minimum lease position, thereby releasing the band.
throttle, vehicle speed will decrease gradually (coast- 3-4 Accumulator: 4th band fluid exhausts from the ac-
down) and the TCM will command a 4-3 downshift. The cumulator. Spring force and 3-4 accumulator feed fluid
TCM will also initiate a 4-3 downshift if engine load is in- pressure move the accumulator piston to the third gear
creased with throttle position remaining the same (for position.
example, driving up a steep hill).
1-2/3-4 Accumulator Valve: The accumulator valve
Line Pressure Increases regulates line pressure into the 1-2/3-4 accumulator fluid
Pressure Control Solenoid (PCS): During the down- circuit to fill the 3-4 accumulator. This regulation is basi-
shift, except for a coastdown, the TCM senses the in- cally controlled by torque signal fluid pressure. In-
crease in throttle position or engine load and increases creased torque signal fluid pressure regulates
the PCS duty cycle. The increase in duty cycle in- accumulator fluid to a higher pressure.
creases output fluid pressure from the PCS, thereby in- #7 Checkball (3-4 Accumulator): 1-2/3-4 accumulator
creasing torque signal fluid pressure at the torque signal fluid pressure seats the #7 checkball and forces accu-
regulator valve. mulator fluid through orifice #28.
Pressure Regulator Valve: Increased torque signal Torque Converter Clutch
fluid pressure acting on the boost valve increases line
The TCM commands TCC release prior to initiating a
pressure at the pressure regulator valve.
4-3 downshift. When the TCC is in the release position,
Intermediate/4th Band Releases release fluid pressure is routed to the pressure switch
1-2 Shift Solenoid: The TCM de-energizes the normal- assembly. This fluid pressure signals the TCM that the
ly open solenoid and 1-2 signal fluid exhausts. TCC is in the release position. The TCC is not applied
under normal operating conditions in third gear (except
3-4 Shift Valve: 1-2 signal fluid pressure exhausts from
for some applications).
the 3-4 shift valve and spring force moves the valve into
the third gear position. This opens the 4th band fluid cir- 3-2 and 2-1 Downshifts
cuit to an orificed exhaust to help control the band re- Refer to the manual range explanations for a description
lease. of the 3-2 and 2-1 downshifts with respect to the
clutches releasing.

DAEWOO J-100 BL2 / BL3

5A -- 296 4T40-E AUTOMATIC TRANSAXLE

MANUAL THIRD - THIRD GEAR

A103A330

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 297
A manual 4-3 downshift is accomplished by moving the Important: The operating states for the shift solenoids
gear selector lever to the manual third (3) position. In follow the normal operation depending on vehicle driving
manual third, the transaxle is hydraulically prevented conditions. The manual first - first gear illustration
from upshifting into fourth gear under any conditions. shows the solenoids in the third gear position.
Also, the coast clutch is applied in all manual ranges to
TFP: PRND4 fluid exhausts from the TFP and the TFP
provide engine compression braking when appropriate.
signals the TCM that the manual valve is in the manual
The following information explains the additional
third position.
changes during a manual 4-3 downshift as compared to
a forced 4-3 downshift. Refer to Overdrive Range - 4-3 Coast Clutch Applies
Downshift for a complete description of a 4-3 downshift. 3-4 Shift Valve: D321 fluid is routed through the 3-4
Fourth Gear Hydraulically Prevented shift valve and into the coast clutch fluid circuit.
Manual Valve: The manual valve moves into the manu- Coast Clutch: Coast clutch fluid pressure applies the
al third (3) position and line pressure enters the D321 coast clutch. With the coast clutch applied, engine
fluid circuit. Also, the manual valve blocks line pressure compression braking is available in manual third - third
from the PRND4 fluid circuit and PRND4 fluid exhausts gear to slow the vehicle when the throttle is released.
past the manual valve. Manual Third - Second and First Gears
3-4 Shift Valve: D321 fluid pressure assists spring force The transmission operates the same in manual third as
to keep the valve in the third gear position under any in overdrive range with the exception of fourth gear be-
conditions. This opens the 4th band fluid circuit to an ing prevented. The transaxle will upshift and downshift
orificed exhaust and the intermediate/4th band releases, between first, second, and third gears as in overdrive
thereby preventing fourth gear. range. However, engine compression braking is not
available in manual third - first and second gears and
the vehicle will coast when the throttle is released.

DAEWOO J-100 BL2 / BL3

5A -- 298 4T40-E AUTOMATIC TRANSAXLE

MANUAL SECOND - SECOND GEAR

A103A331

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 299
A manual 3-2 downshift is initiated by moving the gear 2-3 Accumulator Valve: The accumulator valve regu-
selector lever to the manual second (2) position. Howev- lates line pressure into the 2-3 accumulator fluid circuit
er, the transaxle will not downshift into second gear until to fill the 2-3 accumulator. This regulation is basically
vehicle speed is below approximately 99 km/h (62 mph). controlled by torque signal fluid pressure. Accumulator
At higher vehicle speeds, the TCM will keep 2-3 shift so- fluid pressure is regulated to a higher pressure with
lenoid energized (ON) and the transaxle will operate in greater torque signal fluid pressure.
manual second - third gear as a safety precaution. In
Intermediate/4th Band Applies
manual second the transaxle is hydraulically prevented
from upshifting into fourth gear under any conditions. 1-2 Shift Valve: 1-2 Shift solenoid is OFF when the
Also, the coast clutch remains applied as in manual third TCM commands second gear and spring force holds the
and provides engine compression braking in third and 1-2 shift valve in the upshifted position. Intermediate
second gears. The transaxle upshifts and downshifts band feed fluid is routed through the valve and into the
between first and second gears as in overdrive range. intermediate band fluid circuit.
Manual Valve: Line pressure is routed into the D21 fluid #3 Checkball (Intermediate Band Apply): Intermedi-
circuit when the selector lever is moved into the manual ate band fluid pressure seats the #3 checkball and is
second (2) position. Line pressure continues to feed the forced through the #8 orifice. This orifice helps control
D321 fluid circuit as in manual third. the intermediate band apply.
2-3 Shift Solenoid: The TCM de-energizes 2-3 shift so- Intermediate/4th Servo: Intermediate band fluid pres-
lenoid when vehicle operating conditions are appropri- sure is routed to the inner area of the intermediate/4th
ate for 3-2 downshift. With the solenoid OFF 2-3 signal servo piston. This fluid pressure moves the servo piston
fluid exhausts through 2-3 shift solenoid. and apply pin to apply the intermediate/4th band. The
band provides engine compression braking in manual
2-3 Shift Valve: Spring force moves the 2-3 shift valve
second - second gear.
into the second gear position when 2-3 signal fluid ex-
hausts. D21 fluid continues through the valve and is also Pressure Control
routed into the intermediate band feed fluid circuit. 3-4 TFP: D21 fluid from the 2-3 shift valve is routed to the
drive fluid, which feeds the direct clutch, exhausts past TFP. The TFP signals the TCM that the manual valve is
the 2-3 shift valve. in the manual second position.
Direct Clutch Releases Pressure Control Solenoid: The TCM increases the
Direct Clutch: Direct clutch fluid exhausts and the di- PCS duty cycle to increase the operating range of
rect clutch releases. torque signal fluid pressure in manual second. This pro-
vides increased line pressure for the additional torque
2-3 Accumulator: Direct clutch feed fluid exhausts from
requirements during engine compression braking and
the 2-3 accumulator, unseats the #5 checkball and ex-
increased engine load in manual second.
hausts past the 2-3 shift valve. 2-3 accumulator feed
fluid seats the #6 checkball and fluid is routed through Torque Converter Clutch: The TCM will release the
orifice #27 to control accumulator feed pressure as di- TCC before downshifting into manual second. The TCC
rect clutch feed fluid exhausts. will not re-apply in second gear under normally operat-
ing conditions.

DAEWOO J-100 BL2 / BL3

5A -- 300 4T40-E AUTOMATIC TRANSAXLE

MANUAL FIRST - FIRST GEAR

A103A332

DAEWOO J-100 BL2 / BL3

 4T40-E AUTOMATIC TRANSAXLE 5A -- 301
A manual 2-1 downshift is initiated by moving the gear Second Clutch Releases
selector lever to the manual first (1) position. However, Second Clutch: 2nd clutch fluid exhausts from the
the transaxle will not downshift into first gear until ve- clutch piston and through the 2-3 drive fluid circuit. This
hicle speed is below approximately 60 km/h (37 mph). releases the 2nd clutch and the transaxle operates in
At higher vehicle speeds the TCM will keep 1-2 shift so- first gear.
lenoid de-energized (OFF) and the transaxle will oper-
ate in manual first - second gear. In manual first, the 1-2 Accumulator: 2nd clutch feed fluid exhausts from
transaxle is electronically prevented from upshifting into the 1-2 accumulator, exhausts past the #2 checkball and
third or fourth gears under any conditions. Also, the through the 2-3 drive fluid circuit. 1-2 accumulator feed
coast clutch remains applied, as in manual third and fluid fills the 1-2 accumulator as 2nd clutch fluid ex-
manual second, and provides engine compression brak- hausts.
ing in first and second gears. 1-2/3-4 Accumulator Valve: The accumulator valve
Manual Valve: Line pressure is routed into the LO fluid regulates line pressure into the 1-2/3-4 accumulator
circuit when the selector lever is moved into the manual fluid circuit to fill the 1-2 accumulator. This regulation
first (1) position. Line pressure continues to feed the is basically controlled by torque signal fluid pressure.
drive, D321 and D21 fluid circuits as in manual second. Accumulator fluid pressure is regulated to a higher
pressure with greater torque signal fluid pressure.
TFP: LO fluid pressure is routed to the TFP and the TFP
signals the TCM that the manual valve is in the manual TCC Control Solenoid: Filtered 2-3 drive fluid ex-
first position. hausts from the solenoid and through the 2-3 drive fluid
circuit.
#1 Checkball (LO/PRN): LO fluid pressure seats the
#1 checkball against the PRN fluid circuit and fills the Intermediate Band Releases
LO/PRN fluid circuit. LO/PRN fluid is routed to the 1-2 Intermediate/4th Servo: Intermediate band fluid ex-
shift valve. hausts from the servo piston, spring force moves the
1-2 Shift Solenoid: 1-2 shift solenoid is energized by piston and apply pin and the intermediate/4th band re-
the TCM when vehicle speed is below approximately 30 leases. However, the intermediate/4th band remains ap-
to 35 mph. 1-2 signal fluid is blocked from exhausting plied in manual first - second gear to achieve engine
through the solenoid. compression braking.
1-2 Shift Valve: 1-2 signal fluid pressure shifts the valve
Lo/Reverse Band Applies
into the downshifted position against spring force and
the following changes occur: Lo/Reverse Servo: Lo/band fluid pressure is routed to
the inner area of the lo/reverse servo to apply the lo/re-
D The 2-3 drive fluid circuit is open to an exhaust past
verse band. The lo/reverse band provides engine com-
the valve.
pression braking when the throttle is released in manual
D Intermediate band fluid is exhausted past the valve. first - first gear.
D LO/PRN fluid is routed into the lo band fluid circuit. Important: Manual first - third gear is also possible at
high speeds as a safety feature.

DAEWOO J-100 BL2 / BL3