Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 1

7E4 – 1

Section 7E4

Hydra-Matic 5L40-E Automatic Transmission –

On-Vehicle Servicing

ATTENTION

Before performing any Service Operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Information ...............................................................................................................................3

1.1 General Service Precautions ................................................................................................................................ 3

Recommendations................................................................................................................................................. 3

Oil Cooler Pipes..................................................................................................................................................... 4

Cleaning and Inspection ....................................................................................................................................... 4

2 Maintenance Operations........................................................................................................................5

2.1 Transmission Fluid Check .................................................................................................................................... 5

General Information............................................................................................................................................... 5

Transmission Fluid Colour....................................................................................................................................5

Using TECH 2 To Check Fluid Temperature........................................................................................................ 5

Transmission Fluid Checking Procedure ............................................................................................................ 6

2.2 Transmission Cooler Reverse Flush and Flow Rate Check............................................................................. 11

Reverse Flush ...................................................................................................................................................... 11

Flow Rate Check.................................................................................................................................................. 12

3 On-Vehicle Service Operations...........................................................................................................13

3.1 Fluid Change and Filter Replace ........................................................................................................................ 13

Remove................................................................................................................................................................. 13

Reinstall................................................................................................................................................................ 15

3.2 Selector Linkage.................................................................................................................................................. 16

Remove................................................................................................................................................................. 16

Inspect .................................................................................................................................................................. 16

Reinstall................................................................................................................................................................ 16

Adjust.................................................................................................................................................................... 16

3.3 Shift Selector Assembly...................................................................................................................................... 17

Remove................................................................................................................................................................. 17

Disassemble......................................................................................................................................................... 17

Boot, Shift Lever Knob Remove....................................................................................................................... 18

Patch Harness Remove ................................................................................................................................... 19

Switch Remove................................................................................................................................................ 20

Base Disassembly............................................................................................................................................ 21

Lever Disassembly........................................................................................................................................... 21

Reassemble.......................................................................................................................................................... 22

Base Reassembly ............................................................................................................................................ 22

Lower Housing ................................................................................................................................................. 23

Reinstall................................................................................................................................................................ 25

3.4 Transmission Fluid Cooler Pipes/Hoses ........................................................................................................... 26

Remove................................................................................................................................................................. 26

Transmission Fluid Cooler Pipes...................................................................................................................... 26

Radiator Cooler Pipes/Hoses........................................................................................................................... 27

Reinstall................................................................................................................................................................ 28

Radiator Cooler Pipes/Hoses........................................................................................................................... 28

Transmission Fluid Cooler Pipes...................................................................................................................... 29

Techline

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 2

7E4 – 2

3.5 Fluid Pressure Test Plug..................................................................................................................................... 30

Replace................................................................................................................................................................. 30

3.6 Transmission Mount and Mount Plate ............................................................................................................... 31

Inspect .................................................................................................................................................................. 31

Remove................................................................................................................................................................. 32

Reinstall................................................................................................................................................................ 33

3.7 Output Drive Flange and Oil Seal....................................................................................................................... 34

Remove................................................................................................................................................................. 34

Reinstall................................................................................................................................................................ 36

3.8 Extension Housing .............................................................................................................................................. 38

Remove................................................................................................................................................................. 38

Reinstall................................................................................................................................................................ 39

3.9 Transmission Internal Electrical Harness.......................................................................................................... 40

Replace................................................................................................................................................................. 40

3.10 Manual Shaft Oil Seal .......................................................................................................................................... 43

Replace................................................................................................................................................................. 43

3.11 Manual Shaft Position Switch............................................................................................................................. 45

Remove................................................................................................................................................................. 45

Reinstall................................................................................................................................................................ 47

3.12 Input Speed Sensor............................................................................................................................................. 49

Replace................................................................................................................................................................. 49

3.13 Output Speed Sensor.......................................................................................................................................... 50

Replace................................................................................................................................................................. 50

3.14 1-2 Shift Solenoid................................................................................................................................................. 51

Replace................................................................................................................................................................. 51

3.15 2-3 Shift Solenoid................................................................................................................................................. 52

Replace................................................................................................................................................................. 52

3.16 4-5 Shift Solenoid................................................................................................................................................. 54

Replace................................................................................................................................................................. 54

3.17 Pressure Control Solenoid.................................................................................................................................. 55

Replace................................................................................................................................................................. 55

3.18 Torque Converter Clutch (TCC) PWM Solenoid................................................................................................ 57

Replace................................................................................................................................................................. 57

3.19 Solenoid Leak Testing......................................................................................................................................... 59

3.20 Control Valve Body and Accumulator Assembly.............................................................................................. 60

3.21 Transmission Control Module (TCM)................................................................................................................. 61

Remove................................................................................................................................................................. 61

Reinstall................................................................................................................................................................ 61

TCM Programming Procedure............................................................................................................................ 62

3.22 5L40-E Automatic Transmission ........................................................................................................................ 63

Remove................................................................................................................................................................. 63

Reinstall................................................................................................................................................................ 68

Transmission Final Test and Inspection............................................................................................................ 70

3.23 Torque Converter and/or Seal............................................................................................................................. 71

Replace................................................................................................................................................................. 71

4 Specifications.......................................................................................................................................74

5 Torque Wrench Specifications............................................................................................................76

6 Special Tools ........................................................................................................................................77

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 3

7E4 – 3

1 General Information

The service operations detailed in this Section, relate to tasks that can be carried out on the 5L40-E Automatic

Transmission while it is still installed in the vehicle. In addition, the procedures required to remove and reinstall the

transmission assembly and torque converter from/to the vehicle are also provided.

It is strongly recommended that the General Service Precautions provided in this Section be read and followed,

whenever servicing operations are to be carried out on this transmission.

1.1 General Service Precautions

ATTENTION

All fasteners are important attaching parts as they affect the performance of vital components and/or could

result in major repair expense. W h ere specified in this section, fasteners MUST be replaced with parts of the

same part number or an approved equivalent. Do not use fasteners o f an inferior quality or substitute design.

Torque values must be used as specified during reassembly to ensure proper retention of all components.

Throughout this section, fastener torque wrench specifications may be accompanied with the following

identification marks:

 Fasteners must be replaced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

Recommendations

When servicing this transmission, all parts should be cleaned and inspected as outlined under 'Cleani ng and Inspection',

in this Section. Individual units should be reassembled before disassembly of other units to avoid confusion and

interchanging of parts.

Machined surfaces of alloy transmission

components (e.g. transmission case) have

extremely sharp edges that are a very real

safety hazard. It is recommended that

machined edges are ‘broken’ with a sharp

second cut file, taking care not to allow metal

particles to enter the transmission.

1 Thoroughly clean the transmission exterior before removal of any component.

2 Disassembl y and reassembly must be made on a clean work bench. Cleanliness is of the utmost importance. The

bench tools, and parts must be kept clean at all times.

3 Before installin g screws and other fasteners into aluminium parts, dip screws into transmission fluid (Only use

Dexron® III) to prevent galling of the aluminium threads and to prevent screws from seizing.

4 To prevent thread stripping, always use a torque wrench when insta lling fasteners.

5 If threads in aluminium parts are stripped or damaged, the part can be recovered by the use of commercially

available, thread inserts.

6 Protective tools must be used when assembling seals to prevent damage. The slightest flaw in the sealing surface

of the seal can cause a fluid leak.

7 Aluminium cast ings and valve parts are very susceptible to nicks, burrs, etc., and should be handled with care.

8 Internal snap rings should be expanded and external snap rings compressed if they are to be re-used. This will

ensure proper seatin g when reinstalled.

9 O-rings, gaskets and oil seals that are removed, should be replaced with ne w parts.

10 Teflon oil seal rings shoul d not be removed unless damaged.

11 During assembly of each unit, all internal moving parts must be lubricated with new transmission fluid of th e correct

specification.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 4

7E4 – 4

Oil Cooler Pipes

Should any transmission fluid cooling pipe suffer accidental damage, then a genuine replacement pipe must be fitted.

Refer to the current release of PartFinder™ to determine the correct part n umber for the specific engine and pipe

involved. Reworking of damaged pipes or hand made replacements are not permitted.

Cleaning and Inspection

Wear eye protection to prevent potential

injury.

After the complete disassembly of a compon ent, wash all metal parts in a clean solvent and dry with compressed air.

Blow oil passages out and check to make sure they are not obstructed. Small passages shou ld be checked with tag wire.

All parts should be inspected to determine which parts are to be replaced.

Pay particular attention to the follo wing:

1 Inspect linkage and pivot points for excessive wear.

2 Bearing and thrust surfaces of all parts should be checked for exc essive wear and scoring.

3 Check for broken seal rings, damaged ring lands and damaged threads.

4 Inspect seal and O-rings.

5 Mating surfaces of castings should be checked for burrs. Irregularities may be removed by lapping the

surface with emery paper. The emery paper is laid on a flat surface, such as a piece of plate glass.

6 Castings should be checked for cracks and porosit y.

7 Do not use solv ents on neoprene seals, composition faced clutch plates or thrust washers, as damage to

these parts may occur.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 5

7E4 – 5

2 Maintenance Operations

ATTENTION

All fasteners are important attaching parts as they affect the performance of vital components and/or could

result in major repair expense. W h ere specified in this section, fasteners MUST be replaced with parts of the

same part number or an approved equivalent. Do not use fasteners o f an inferior quality or substitute design.

Torque values must be used as specified during reassembly to ensure proper retention of all components.

Throughout this section, fastener torque wrench specifications may be accompanied with the following

identification marks:

 Fasteners must be replaced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

2.1 Transmission Fluid Check

General Information

When adding or changing the transmission fluid, use only Dexron® III automatic transmission fluid. Refer to the

appropriate Owner's Handbook for servicing intervals.

Because this transmission fluid changes colour and develops an odour very early in its lif e, these indicators should not

necessarily be relied upon to diagnose either transmission internal condition nor fluid deterioration.

If, when following the Fluid Checking Procedure, a dark brown fluid colour is observed, coupled with a reported delayed

shift pattern, this may only indicate that the fluid requires replacement and alone, is not a definite indication of a potential

transmission failure.

NOTE

Do not overfill the transmission. Overfilling will

cause foaming of the fluid, loss of fluid, shift

complaints and possible damage to the

transmission.

Transmission Fluid Colour

Transmission fluid colour when new and unused, is red. A red dye is added so that it can be distinguished from other oils

and lubricants. The red dye is not an indicator of fluid quality and is not permanent. As the vehicle is driven, the

transmission fluid will quickly begin to look darker in colour. The colour will then appear light brown. A DARK brown

colour with a distinctively burnt odour MAY in dicate fluid deterioration and a need for the fluid to be changed.

Using TECH 2 To Check Fluid Temperature

1 Connect the TECH 2 scan to ol to the ALDL connector in the vehicle, then press the 'ON' button, to activate the

scan tool.

2 At the 'Main Menu', select 'F0: Diagnostics / Model Year (05) 2005 / Vehicle Type'.

3 At the 'System Select' menu, select 'F1: T r ansmission / Automatic Transmission’, turn ‘Ignition ON', then 'Confirm'

with the Soft Key.

4 At the 'Transmission Ide ntifier' screen, press the 'Confirm' soft key once again, to show the 'Transmission

Application' menu.

5 From the functions sho wn, select 'F 2: Data Displa y', then scroll d own until the 'Transmission Fluid Temperature'

display is visible.

Techline

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 6

7E4 – 6

Transmission Fluid Checking Procedure

Legend

1 Fluid level plug.

2 Fluid drain plug.

Figure 7E4 – 1

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 7

7E4 – 7

Step Action Value Yes No

1 1 Start the engine.

2 Depress the brake pedal and move the shift

lever through all of the gear ranges, pausing a

few seconds in each range. Return the shift

lever to the Park range.

3 Raise the vehicle and support in a safe manner.

The vehicle must be level, the eng ine running

and the shift lever in the Park range. Refer to

Section 0A General Information for the location

of recommended lifting and support poi nts.

• The engine must be running when

the transmission fluid filler plug is

removed, or exce ssi ve fluid loss w ill

occur.

• Take extreme care when removing

the filler plug as it is very close to

the catalytic converter and personal

injury through burning can easily

occur.

• Transmission fluid may be hot.

Since the actual fluid level is

unknown, stand clear when

removing the filler plug. Have a

container ready to capture any lost

fluid.

• Do not turn the engine off with the

filler plug removed, as you can be

injured by hot transmission fluid

being expelled out of the fluid level

plug opening.

4 Remove the transmission fluid level plug (1).

See Figure 7E4-1 for the loc ation.

5 Inspect the fluid colour. If necessary, use a

small screwdriver as a dipstick.

NOTE

The transmission fluid may darken with

normal use and does not always indicate

contamination or oxidation.

Is the fluid colour red or light brown with no burnt

odour?

–

Go to Step 4 Go to Step 2

2 Does the fluid have a burnt odour or a dark brown

colour? – Go to Step 8 Go to Step 3

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 8

7E4 – 8

Step Action Value Yes No

3 Does the fluid have a cloudy or milky appearance? – Go to Step 7 Go to Step 8

1 Let the fluid temperature rise until it has reached

the specified value. Check temperature using

TECH 2.

2 Check the fluid level. The level should be even

with the bottom of the threaded plug hole.

Is the fluid level low?

30 – 50° C

Go to Step 5 Go to Step 11

5 1 Add Dexron® III automatic transmission fluid in

increments of 0.5 litre until the fluid drains from

the filler plug hole.

Did you add more than 1.5 litres to the transmission?

–

Go to Step 6 Go to Step 11

6 1 The transmission may have a leak. Refer to

Fluid Leak Diagnosis in Section 7E3 Automatic

Transmission – Hydrau lic/Mechanical

Diagnosis.

Was a transmission leak found?

–

Go to Step 9 Go to Step 11

7 1 The transmission fluid is contaminated with

engine coolant.

2 Repair or replace the transmission cooler in the

radiator.

Is the transmission cooler repair complete?

–

Go to Step 9 –

8 1 Drain the fluid by removing the transmission

fluid pan drain plug (2).

2 Remove the transmission fluid pan. Refer to

3.1 Fluid Change and Filter Replace.

NOTE

A very small amount of material in the

bottom of the pan is a normal condition.

3 Inspect the bottom pan for an y excessive debris.

Was excessive debris found?

–

Go to Step 9 Go to Step 10

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 9

7E4 – 9

Step Action Value Yes No

9 1 Repair/replace the transmission, as required.

NOTE

If the transmission is replac ed/overhauled,

then flushing the fluid cooler and pipes will

be required. Refer to 2.2 Transmission

Cooler/Lines Reverse Flush and Flow

Rate Check, in this Section.

2 Add enou gh Dexron® III automatic transmission

fluid to bring the fluid to the fluid level to the

bottom of the threaded filler plug hole.

3 Start the engine and ru n at idle speed.

4 Depress the brake pedal and move the shift

lever through all of the gear ranges, pausing a

few seconds in each range. Return the shift

lever to the Park range.

5 Raise the vehicle and support in a safe manner.

The vehicle must be level, the eng ine running

and the shift lever in the Park range. Refer to

Section 0A General Information for the location

of recommended lifting and support poi nts.

• The engine must be running when

the transmission fluid filler plug is

removed, or exce ssi ve fluid loss w ill

occur.

• Take extreme care when removing

the filler plug as it is very close to

the catalytic converter and personal

injury through burning can easily

occur.

• Transmission fluid may be hot.

Since the actual fluid level is

unknown, stand clear when

removing the filler plug. Have a

container ready to capture any lost

fluid.

• Do not turn the engine off with the

filler plug removed, as you can be

injured by hot transmission fluid

being expelled out of the fluid level

plug opening.

6 With TECH 2 still connecte d to the vehicle, allow

the A/T fluid temperature to rise until it has

reached the specified value. Remov e the

transmission filler plug.

7 If needed, add DEXRON®III automatic

transmission fluid in increments of 0.5 litre until

the fluid drains from the threaded filler plug hole.

8 Allow fluid to finish dr aining from the filler plug

hole. Inspect the filler plug (1) and O-ring and , if

undamaged, may be re-used. Reinstall the

transmission filler plug (1) and tighten to the

specified value.

9 Wipe any excess fluid from the transmission

with a rag or shop towel.

Is the repair complete?

30 – 50° C

20 N.m

System OK –

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 10

7E4 – 10

Step Action Value Yes No

10 1 Change the fluid and fluid filter. Refer to

3.1 Fluid Change and Filter Replace.

2 Start the engine and ru n at idle speed.

3 Depress the brake pedal and move the shift

lever through all of the gear ranges, pausing a

few seconds in each range. Return the shift

lever to the Park range.

4 Raise the vehicle and support in a safe manner.

The vehicle must be level, the eng ine running

and the shift lever in the Park range. Refer to

Section 0A General Information for the location

of recommended lifting and support poi nts.

• The engine must be running when

the transmission fluid filler plug is

removed, or exce ssi ve fluid loss w ill

occur.

• Take extreme care when removing

the filler plug as it is very close to

the catalytic converter and personal

injury through burning can easily

occur.

• Transmission fluid may be hot.

Since the actual fluid level is

unknown, stand clear when

removing the filler plug. Have a

container ready to capture any lost

fluid.

• Do not turn the engine off with the

filler plug removed, as you can be

injured by hot transmission fluid

being expelled out of the fluid level

plug opening.

5 With TECH 2 still connecte d to the vehicle, allow

the A/T fluid temperature to rise until it has

reached the specified value. Remov e the

transmission filler plug (1).

6 If needed, add Dexron® III automatic

transmission fluid in increments of 0.5 litre until

the fluid drains from the threaded filler plug hole.

7 Allow fluid to finish dr aining from the filler plug

hole. Inspect the filler plug (1) and O-ring and , if

undamaged, they may be re-used. Reinstall the

transmission filler plug (1) and tighten to the

specified value.

8 Wipe any excess fluid from the transmission

with a rag or shop towel.

Is the repair complete?

30 – 50° C

20 N.m

System OK –

11 1 With TECH 2 still connected to the vehicle, allow

the A/T fluid temperature to rise until it has

reached the specified value. Remov e the

transmission filler plug (1).

2 Allow fluid to finish dr aining from the filler plug

hole. Inspect the filler plug (1) and O-ring and , if

undamaged, they may be re-used. Reinstall the

transmission filler plug (1) and tighten to the

specified value.

3 Wipe any excess fluid from the transmission

with a shop towel or rag.

Is the repair complete?

30 – 50° C

20 N.m

System OK –

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 11

7E4 – 11

2.2 Transmission Cooler Reverse Flush and

Flow Rate Check

It is essential that a reverse flush and oil

cooler flow rate check is p erformed, after ANY

of the following situations:

• Transmission is replaced.

• Fluid contamination is suspected.

• Whenever the oil pump and/or torque

converter is replaced.

NOTE

The reverse flush must be completed prior to

conducting a flow rate check.

Reverse Flush

The recommended proce dure for reverse flushing the transmission cooler and lines, particularly after an overhauled or

replaced transmission has been installed into the vehicle, is as follows:

1 Disconnect the cooler l ine flange at the transmission and the quick connect fittings at the radiator cooler end.

Refer to 3.4 Transmission Cooler Pi pes/Hoses, in this Section. Do not lose the pipe sealing O-rings, when they are

removed.

2 Disconnect the cooler p ipe/hose combinations from the radiator, right hand tank.

Refer to 3.4 Transmission Cooler Pi pes/Hoses, in this Section.

3 Carefully check the cooler inlet fitting (upper) at the radiator end, to see whether any material is evident at this

point. If so, dislodge and remove with a suitable tool and/or compressed air blown in the reverse direction through

the cooler.

4 Using a comm ercially available pressure spray gun and clean solvent, such as white spirit:

a Back flush through all co oler lines and hoses.

b Back flush through the cooler, including an external cooler (if fitted).

c Blow compressed air through the cooler and all cooler lines and hoses, to remove solvent.

d Flush the cooler and pipes/hoses with transmission fluid.

5 Check the cooler pipe to cooler fitting and cooler pipe to transmission flange, sealing O-rings for damage, replacing

as required.

6 Lubricate al l O-rings with automatic transmission fluid before installing.

7 Reconnect cooler pi pes to the cooler and transmission (refer to 3.4 Transmission Cooler Pipes/Hoses, in this

Section) but leave the cooler return line to transmission co nnection open at the flexible hose, quick connect fitting

from the lower cooler fitting.

8 Tighten the co oler pipe flange nuts at the cooler end to the specified torque.

Refer to 3.4 Transmission Cooler Pipes/Hoses, Reinstall for the correct procedure.

Oil cooler pipe to radiator fitting

torque specification..............................................25 N.m

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 12

7E4 – 12

9 Tighten the co oler pipe flange (3) to transmission

housing retaining bolt (2) to the correct torque

specification.

Fluid cooler pipe flange bolt

to transmission torque specification.....................20 N.m

Figure 7E4 – 2

10 Conduct a flow rate test as described next, to ensure that any restriction has been cleared.

11 If flow rate is satisfactory, reconnect the return line, quick connect fitting.

Refer to 3.4 Transmission Cooler Pipes/Hoses, in this Section.

12. Check fluid level as detailed in 2.1 Transmission Fluid Check, in this Section.

13 Lower vehicle to the ground and road test to check for correct operation.

Flow Rate Check

Do not run engine any longer than absolutely

necessary, as too low a fluid level can cause

aeration and foaming.

1 Follo wing the flushing of the transmission cooler, pipes and flexible hoses, leave the cooler return line to

transmission connection open at the flexib le hose, quick connect fitting from the lower cooler fitting.

2 Ensure that the fluid is at the recommended level, refer to 2.1 Transmission F luid Check, in this Section.

3 Place an empty, clean container underneath the disconnected cooler hose. Clip the hose to the container.

4 With the selector lever in the PARK position, have an assistant start the engine and run at idle speed.

5 Observe the fluid flo w into the container, after all air bubbles have ceased a nd a steady flow is evident. Measure

the flow rate.

Result: The fluid flow rate should be approximatel y 1.9 litres in a 30 second period, with cold automatic

transmission fluid (ATF). W ith AT F at normal operating temperature (86 – 93° C), the flow rate will increase and

should be approximatel y 3 litres in a 30 second period.

If the flow rate is less than this specification, the source of the restriction must be located and rectified. Possibilities

are either radiator tank cooler, faulty flexible hose/s and/or external cooler (if fitted).

6 Reinstall the cooler return line to the transmission quick connect.

Refer to 3.4 Transmission Cooler Pi pes/Hoses, Reinstall for the correct procedure.

7 Clean up an y spilled automatic transmission fluid, start the engine and check for fluid leaks.

8 Check and correct the fluid level as detailed in 2.1 Transmission Fluid Check, in this Section, topping up as

required.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 13

7E4 – 13

3 On-Vehicle Service Operations

ATTENTION

All fasteners are important attaching parts as they affect the performance of vital components and/or could

result in major repair expense. Where specified in this Section, fasteners MUST be replaced with parts of the

same part number or an approved equivalent. Do not use fasteners o f an inferior quality or substitute design.

Torque values must be used as specified during reassembly to ensure proper retention of all components.

Throughout this section, fastener torque wrench specifications may be accompanied with the following

identification marks:

 Fasteners must be replaced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

3.1 Fluid Change and Filter Replace

Remove

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information in this Service Information

for the location of recommended lifting and supp ort points.

2 Place a suitable drain pan under the transmission fluid drain plu g.

Wear eye protection and protective clothing

to prevent potential scalding from hot

automatic transmission fluid.

3 Remove and discard the transmission fluid drain plug

(2) and seal.

4 Allow the transmission fl uid to drain.

5 Inspect the transmission fluid for discoloration and

contamination while draining.

6 After the fluid has stopped draining, install a NEW

transmission drain plug (2) and seal, then tighten the

plug to the correct torque specification.

Drain plug torque specification.............................20 N.m

Figure 7E4 – 3

Techline

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 14

7E4 – 14

7 Remove the fluid pan bolts.

The fluid pan will retain a residual quantity of

fluid that can splash, as w ill the fluid draini ng

from the transmission components

8 Lightly tap the fluid pan (2) with a rubber mallet if

necessary, to loosen.

9 Remove the fluid pan (2) and the gasket (4).

NOTE

The fluid pan gasket is re-usable, if undama ged.

10 Clean and inspect the following for damage or wear;

a Magnet (1)

b Fluid pan (2)

c Bolts (3)

d Fluid pan gasket (4)

Figure 7E4 – 4

Do not lose the fluid filter neck spacer,

following the filter removal.

11 Remove the fluid filter (1). Use a long screwdriver to

prise the fluid filter neck from the seals in the fluid

pump housing.

Figure 7E4 – 5

12 Using slide hammer, Tool No. J 6125-1B a nd remover

J 23129, remove the two filter neck seals (57) from the

transmission case. Discard the removed seals.

NOTE

If the filter is not being replac ed, then removal of

the seals is not necessary

Figure 7E4 – 6

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 15

7E4 – 15

Reinstall

1 Coat the two 2 fluid filter seals (1) (supplied with a

replacement filter assembly) with petroleum jell y (e.g.

Vaseline™ or equivalent), then install into the

transmission fluid filter neck.

Do not install the fluid filter without the

spacer sleeve being fitted to the filter neck.

2 Install a NEW transmission flu id filter (2) and spacer

sleeve into the case.

Figure 7E4 – 7

3 After checking that the magnet (1) is in the correct

location in the fluid pan (2), install the flui d pan (2) and

the gasket (4) at the same time.

4 Reinstall the fluid pan bolts (3), tightening to the

correct torque specification.

Fluid pan bolt

torque specification..............................................11 N.m

5 Fill the transmission to the corr ect level. Refer to

2.1 Transmission Fluid Check procedure, in this

Section.

6 Lower the vehi cle to the ground.

7 Run the engine and inspect in the oil pan gasket area

for leaks.

8 Lower the vehi cle to the ground and road test for

correct vehicle operation. Figure 7E4 – 8

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 16

7E4 – 16

3.2 Selector Linkage

Remove

1 Set transmission selector lev er to the Park positi on.

2 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of the

recommended jacking and support po ints.

3 Remove lockin g bolt (1), dish ed washer (2), flat

washer (3), insulator (4) and sleeve (5) from lower end

of selector lever (9).

4 Slide trunnion (6) from selector rod (7).

5 While holding the transmission selector lever with an

adjustable wrench, remove retaining nut (8), rod and

lever assembly (7) from transmission manual shaft.

Inspect

Check all items for wear and/or damage, replace all worn or

damaged items.

Figure 7E4 – 9

Reinstall

Reinstallation is the reverse of the removal procedure, except for:

1 While holding the selector lever with an adjustable wrench, tighten the retaining nut (8) to the correct torque

specification.

Manual shift shaft lever

nut torque specification........................................ 12 N.m

NOTE

Do not tighten the selector lever locking bolt (1)

until the adjustment procedure is completed.

2 Adjust the selector linkage as described next.

Adjust

Refer to Figure 7E4 – 9.

1 Loosen lockin g bolt (1) at shift selector lever (9).

2 Position transmission shift selector lever in the Park position.

3 Position transmission manual shaft lever in the Park position (lever fully clockwise), then tighten the locking bolt at

the shift selector lever, to the specified torque.

Shift selector lever locking

bolt torque specification.......................................30 N.m

4 Lower vehicle and test that the vehicle operates correctly.

5 Ensure that engine can only be started in Park and Neutral.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 17

7E4 – 17

3.3 Shift Selector Assembly

Remove

1 Raise vehicle support in a safe manner. Refer to Section 0A General Information for the location of recommend ed

jacking and support points.

2 Remove floor c onsole cover, lower extension side trim

panels and the floor console assembly.

Refer to Section 1A3 Instrument Panel & Console.

3 Disconnect the wiring harness connector from the

selector patch harness.

4 From beneath the vehicle, disconnect the selector rod

and trunnion from the shift selector lever.

Refer to 3.2 Selector Linkage in this Section.

5 Remove the four nuts securing the selector lever

assembly to the floor pan.

6 From inside the vehic le, lift the selector lever assembly

from the floor pan.

Figure 7E4 – 10

Disassemble

1 Using a commercially available Torx Plus (TX2 0) bit

and suitable equipment, remo ve the self tapping screw

(1). Select ‘D’ Drive.

Figure 7E4 – 11

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 18

7E4 – 18

2 Using a small s c rewdriver (2), prise the locking tab on

the wiring harness connector (1) at the rear of the shift

selector assembly, while pushing away from the lower

housing, as shown.

Figure 7E4 – 12

3 With the wiring harness connector free, disconnect the

lower housing from the base (1) b y pressi ng the tangs

on each of the retaining legs (two front, one rear).

4 Lift the lower housing (1) from the base (2), together

with the switch/es, patch wiring harness, boot and shift

lever knob. Set the assembly to one side.

5 As required, lift the insul ator (3) from the base (2) and

set to one side.

Figure 7E4 – 13

With the shift lever assembly now separated, select from the following choices for the service operation/s requir ed.

Boot, Shift Lever Knob Remov e

1 While hold ing the lower housing in an inverted

position, gently prise each of the four securing lugs (1)

to free the cover (2) from the lower housing (3). Lift the

lower housing (3) from the gearshift selector knob,

boot and upper cover assembl y (2) and set to one

side.

NOTE

If the lower housing assembly is not inverted

before separation, then the boot will probably

become dislodged from the locating tangs in the

upper cover.

2 If boot replacem ent is required, free the boot from the

upper cover locating tangs and set the cover to one

side, being careful not to dislo dge nor damage the

PRNDL indicator lens in the process. Figure 7E4 – 14

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 19

7E4 – 19

3 Turn the boot (2) inside out, over the gearshift selector

knob, then cut the plastic tie (1) securing the boot to

the knob. Remove the boot from the gearshift lever

knob and discard.

NOTE

The plastic tie is a unique design and is

markedly different from the usual cable tie.

Figure 7E4 – 15

• The knob is spring loaded and may fly

free once dislodged.

• Take care when releasing th e plated kn ob,

as it is easily scratched.

4 If the gearshift knob needs to be dism antled, use a

small knife (2) or similar to free the lugs securing the

control rod button from the gearshift knob (1) .

5 Remove the two Phillips head self tapping screws,

(located under the control rod button), then separate

the knob components.

Figure 7E4 – 16

Patch Harness Remove

1 Remove the selector indicator lamp and holder from

the switch housing by turning the lamp hol de r 90° to

the left (counter-clockwise), then pull.

Figure 7E4 – 17

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 20

7E4 – 20

2 If not removed previously (step 3), release the switch

connector retaining lug/s, then remove the

connector/s.

NOTE

While each switch patch harness connector is

the same colour (white), the Power/Economy

(“PWR”) switch (when fitted) connector wiring is

taped to the PRNDL indicator lamp wiring, as

this switch will always be on the same side as

this lamp.

Figure 7E4 – 18

Switch Remove

NOTE

For this operation, the cover must be split from

the lower housing. Refer to Step 4 in the

Disassembly procedure.

1 To remove the PWR and/or A/S switch (if fitted), use a

small bladed screwdriver and lever one of the switch

retaining tangs from under the lower housing to free

the particular switch, cock to one side, release the

second tang and then remove the switch from above.

NOTE

Take note of the locating lug on the switch body

that ensures the correct orientation of the switch

when reinstalled.

Figure 7E4 – 19

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 21

7E4 – 21

Base Disassembly

1 If not removed previously, remove the shift ro d trunnion bolt from the lower end of the shift lever arm. Slide the

trunnion from the arm, then remove the insulating grommet.

NOTE

This is necessary to provide clearance for the

lever to be removed from the lower housing.

1 Remove the external seal (1) from the lever arm and

set to one side.

Figure 7E4 – 20

2 To remove the lever l ockin g piece, use a small

screwdriver (1) to lever the locking tan g free while

pulling on the locking piece (2) with long nosed pliers

(3).

3. Push the lever assembly inwards to release the inner

support pin and bush

NOTE

The bush may remain in the lower housing.

4 Lift the shift lever from the lower housing.

NOTE

While it will be necessar y to manoeuvre the l ever

somewhat, sufficient space is provided to

overcome any need to apply force to the lever

assembly.

Figure 7E4 – 21

Lever Disassembly

Further disassembly of the base is not recommended, as there is a very r eal possibility that, during reinstallation of the

roll pin, the shift lever will be c r acked, unless sophisticated jigs are used. For this reason, the shift lever is only serviced

as an assembly.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 22

7E4 – 22

Reassemble

Base Reassembly

1 Inspect the external lever, inner bushing (1) for

damage, replacing as requir ed. Lubricate with a multi-

purpose chassis grease such as NLGI No. 1 Lithium

grease.

2 Reinstall the split inner support bush (2) to the selector

lever pin, aligning the split in the bush with the key on

the selector lever pin. Lubricate the external bush

surface with a multi-purpose chassis gr ease such as

NLGI No. 1 Lithium grease.

3 Reinstall the selector lever assembly (3), into the

base. Align the small bush with the aperture in the

base then push across to fully inst all the lever.

Figure 7E4 – 22

4 Reinstall the lever locking piece (1), using long nosed

pliers. Correct reinstallation will have occurred when

an audible click is heard, indicating that the tang on

the locking piece has been installed correctly.

Figure 7E4 – 23

5 Apply a smear of multi-purpose chassis grease such

as NLGI No. 1 Lithium grease to the outer, lipped seal

(1), then reinstall over the external lever.

Figure 7E4 – 24

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 23

7E4 – 23

Lower Housing

1 If removed, reinstall the switch/es to the lower housing, ensuring that the locating lug on the switch body engages

with the slot in the lower housing. If the vehicle is equipped with Active Select control, the correct location for this

switch, is in the right hand aperture, behind the PRNDL indicator lens.

2 Reinstall the p atch wiring harness, ensuring that the switch connector/s connection is correct. Also reinstall the

PRNDL lamp and holder, by inserting an d turning the holder a quarter turn to the left (counter-clockwise).

3 If a new selector lever boot is to be installed, use the tie strap included with the new boot to firmly secure the boot

to the gearshift selector knob. Trim excess length and discard.

4 With the upper cover (1) inv erted, locate th e boot (2)

over each of the cover locating tangs (3), working

gradually around unti l every tang is covered.

NOTE

The weight of the selector knob will be sufficient

to keep the boot engaged with the tangs.

Figure 7E4 – 25

5 To reduce the possibility of the boot from becoming

dislodged from the upper cov er retain ing tangs,

reinstall the lower housing (1 ) to the cover (2), working

in an inverted position, as shown.

NOTE

Before reassembling the lower cover to the

base, check that the coloured indictor is in line

with the two PRNDL displa y lamp holes (3). This

will be the approximate position for correct

reassembly.

6 Engage each of the tabs on the upper cover with the

retaining lugs on the lower housing. When all four tabs

have been engaged, the boot will be clamped and can

no longer become disengaged.

Figure 7E4 – 26

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 24

7E4 – 24

7 Ensure that the PRNDL indicator slide in the lower

housing, is at the “D” position (the red colour will sh ow

opposite the “D” in the PRNDL lens).

8 After checking that the insulator (3) is undamaged,

reinstall to the base (2).

9 After checking that the selector lever is also in the

Drive position, reinstall the lower housing (1 ) over the

shift lever and engage each of the three legs with the

base apertures. Check that the PRND L indicator slide

pin is engaged with the slot in the selector lever.

Figure 7E4 – 27

10 Reinstall the selector indicator lamp and holder (2) by

inserting, then turn to the right (clockwise), to secure.

11 Re-engage the selector lever knob with the selector

lever, aligning the control rod with the ho le in the

selector knob.

NOTE

Correct engagement of the PRNDL indicator can

be easily checked by moving the selector lever.

Should the coloured portion not move with the

lever, then engagement is incorrect. Separate

the lower housing and base and repeat steps 5

to 9 above.

Figure 7E4 – 28

12 Reinstall the selector knob retaining screw, using a TX20 Torx bit and suitable eq uipment, being careful not to

over-tighten.

13 Reinstall the selector lever knob and spring, pushing down until the two locking tangs engage.

NOTE

If the selector lever knob and spring have not

been removed, then re-engagement with the

selector lever can still be achieved but some

manoeuvring may be necessary.

14 If removed, reinstall the wiring harness connector to the bracket at the end of the base and push until the looking

tang engages.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 25

7E4 – 25

Reinstall

1 Clean mating surfaces of floor pan and inspect the

base seal for damage, replacing if necess ary.

2 Reinstall se lector lever assembly (1) to the floor pan,

install the four retaining nuts (2) and tighten to the

correct torque specification.

Shift selector base retaining

nut torque specification........................................ 15 N.m

3 The remainder of the reinstallation is the reverse of the

removal procedure. As required, refer to

Section 1A3 Instrument Panel & Consol e for

installation procedures of the floor cons ole assembly,

lower extension side trim panels and floor console

cover.

4 Adjust shift linkage; refer to

3.2 Selector Linkage, Adjust in this Section, tightening

the selector rod locking bolt to the correct torque

specification.

Shift selector lever locking

bolt torque specification.......................................30 N.m

Figure 7E4 – 29

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 26

7E4 – 26

3.4 Transmission Fluid Cooler Pipes/Hoses

LT Section No. – 04-150

Remove

Transmission Fluid Cooler Pipes

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Place an oil drain tray under the transmission fluid cooler pipes/hoses near the radiator.

3 Check that one of the fluid cooler flexible lines has a

white tag attached and that the mating transmission

cooler pipe has a similar tag. If these have been

removed, apply adhesive tap e to one pair of

pipes/lines to ensure correct reassembly.

4 Remove each of the quick connect security clips by

prising loose with a suitable le ver (i.e. screwdriver).

5 Using disconnect Tool No. AU 525, disconnect each

fluid cooler flexible line (1) from each pipe.

NOTE

The fluid cooler flexible lines are permanently

attached to the radiator fluid cooler pipes.

Figure 7E4 – 30

6 Remove the nut (1) securing the transmission fluid

cooler pipe bracket (2) to the alternator mounting

bracket stud.

Figure 7E4 – 31

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 27

7E4 – 27

7 Remove the screw securing the transmission fluid

cooler pipes bracket to the transmission case.

8 Remove the transmission fluid cooler pipes from the

transmission.

9 Remove the two O-rings and discard, as they must be

replaced on assembly.

Figure 7E4 – 32

Radiator Cooler Pipes/Hoses

NOTE

As the hoses are permanently fitted to the cooler

pipes leading to and from the radiator cooler, if

hose replacement is required, then the complete

pipe/hose combination must be fitted.

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Place an oil drain tray under the transmission fluid cooler pipes/hoses near the radiator.

3 Disconnect the transmissio n cool er pipes from the cooler hoses at the front, lower right side of the engine bay (refer

to Step 3 in the Transmission Fluid Cooler Pipes removal procedure).

4 Referring to Figure 7E 4 – 48, hold the lower cooler nut (4) at the radiator right hand header tank (1) with a back-up

spanner and disconnect the oil cooler fluid return pipe (5) from that location. Plug the o pened connections to

prevent foreign matter entry.

5 Repeat this procedure for the upper cooler nut (2) and pipe/hose assembl y (3) at the radiator right hand header

tank (1).

6 Remove the radiator cooler pipes/hoses (3 and 5) from the vehicle.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 28

7E4 – 28

Figure 7E4 – 33 – Oil Cooler Pipe/Hose Layout

Legend

1 Radiator End Tank – Right

2 Cooler Retaining Nut – Upper 3 Fluid Cooler Pipe – Fluid Feed

4 Cooler Retaining Nut – Lower 5 Fluid Cooler Pipe – Fluid Return

6 Flexible Hoses & Quick Connect Fittings

Reinstall

The installation process of the oil cooler pipes/hoses, is the reverse to removal, except for the following:

Radiator Cooler Pipes/Hoses

1 Before reinstalling e ach p ipe to the cooler, carefully

inspect the pipe O-ring (3). If the centre, silicone

portion shows signs of distress or damage, it must be

replaced.

2 Remove the plugging from the pipe and fittings, fit the

O-ring (3) to the cleaned cooler pipe (2), then reinstall

the pipe into the radiator fluid cooler retaining nut (4).

Always use a back-u p spanner to prevent the

turning of the fluid cooler flare nut fitting (4).

3 Reinstall the tu be nut (1) and tighten to the correct

torque specification.

Cooler pipe tube nut to cooler

fitting torque specification ....................................25 N.m

Figure 7E4 – 34

4 Repeat Steps 1 to 3 for the second pipe/hose assembly.

5 Check and adjust the transmission fluid level, as required. Refer to 2.1 Transmission Fluid Check, in this Section.

6 Inspect for transmission fluid leaks.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 29

7E4 – 29

Transmission Fluid Cooler Pipes

1 Before reinstalling any quick connect fitting, remove plugs from pipes and hose fittings and wipe all exposed parts.

2 Smear, clean automatic transmission fluid over each cooler pipe end, the n push into the flexible hose quick

connect fittings until an audible ' c lick' is heard. As a security check, tug gently on each pipe to ensure correct

engagement.

3 At the transmission end, again clean the pipe ends

and install NEW O-rings (1) after lubricatin g each with

clean, automatic transmission fluid.

4 Install the cooler pipes and bracket (3) to the

transmission case.

5 Reinstall the securing bolt (2) and tighten to the

correct torque specification.

Fluid cooler pipe flange to

transmission bolt torque specification..................20 N.m

Figure 7E4 – 35

6 Reinstall the p ipe bracket retaining nut (1) to the

alternator bracket stud and tighten to the correct

torque specification.

Transmission fluid cooler pipe

bracket nut torque specification ...........................20 N.m

Figure 7E4 – 36

7 Check and top up transmission fluid level as required. Refer to 2.1 Transmission Fluid Check, in this Section.

8 Inspect for transmission fluid leaks.

9 Lower the vehi cle to the ground.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 30

7E4 – 30

3.5 Fluid Pressure Test Plug

LT Section No. – 04-200

Replace

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Using a 5 mm Allen key socket and suitable

equipment, remove the pressure test plug (40) and O-

ring seal (66).

3 Inspect the pressure test hole plug (40) and O-ring

(66) for damage.

4 Install the pressure test plug (40) and O-ring (66), then

tighten the plug to the correct torque specification.

Transmission pressure test plug

to case torque specification..................................11 N.m

5 Check the transmission fluid level, topping up as

required. Refer to 2.1 Transmission Flu id Check, in

this Section.

6 Check for transmission fl uid leaks.

7 Lower vehicle to the grou nd.

Figure 7E4 – 37

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 31

7E4 – 31

3.6 Transmission Mount and Mount Plate

LT Section No. – 04-020

Inspect

To avoid oil pan damage and possible engine

failure, insert a block of wood that spans the

width of the oil pan bottom between the oil

pan and the jack support.

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Raise the transmission to remove the weight from the transmission mount and create slight tension in th e rubber.

3 Observe the transmission mount while raising the transmission. Replace the transmission mount if the mount

exhibits any of the following conditions:

a The hard rubber surface is covered with heat cracks.

NOTE

Black paint on the rubber will crack with time; this

does not constitute a failure.

b The rubber is separated from the metal plate of the transmission mount.

c The rubber is split throu gh the centre of the transmission mount.

4 If there is movement between the metal plate of the transmission mount and its attaching points, lower the

transmission on the transmission mount. T ighten all fasteners attaching th e transmission mount to the frame or

transmission mount bracket to the correct torque specification

Transmission mount plate to extension

housing bolt torque specification..........................55 N.m

Transmission mount to moun t plate

nut torque specification........................................ 55 N.m

Transmission mount to crossmember

nut torque specification........................................ 25 N.m

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 32

7E4 – 32

Remove

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Mark the relationship of the transmissi on mount

crossmember to each body side rail with a felt tipped

pen or similar ('A'). NOTE

This is necessary to maintain alignment on

reassembly.

3 Support the rear of the transmission oil pan with a

block of wood that spans the width of the oil pan

between the oil pan and the ja ck support.

4 Remove the four bolts (1) sec urin g the transmission

mount crossmember to the body side rails.

5 Remove the two nuts (2) securing the transmission

mount to the crossmember (3). Remove the

crossmember from the vehicle. Fig ure 7E4 – 38

6 Remove the two nuts (1) securing the transmission

mount (2) to the transmission mount plate (4), then

remove the mount from the vehicle.

7 If required, remove the two bolts (3) securing the

mount plate (4) to the transmission extension housing,

then remove the plate from the vehicle.

Figure 7E4 – 39

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 33

7E4 – 33

Reinstall

The reinstallation procedure is the reverse to removal, except for the items mentioned here:

1 If removed, reinstall the transmission mount plate to the transmission extension housing and tighten the two bolts

to the correct torque specification.

Transmission mount plate to extension

housing bolt torque specification..........................55 N.m

2 Reinstall the transmission mount to the mount plate, securing with the two nuts tightened to the correct torque

specification.

Transmission mount to moun t plate

nut torque specification........................................ 55 N.m

3 Reinstall the transmission mount crossmember (3),

noting the orientation and aligning the marks (‘A’)

made before removal.

4 Reinstall the fo ur bolts (1) securing the crossmember

(3) to the body side rails and tighten to the correct

torque specification.

Rear crossmember to side

rail bolt torque specification..................................58 N.m

5 Lower the transmission support and remove the block

of wood under the transmission oil pan.

6 Centralise the t r ansmission mount studs in the

crossmember holes, reinstall the nuts and tighten to

the correct torque specification. Figure 7E4 – 40

Transmission rear mount to

crossmember nut torque specification .................25 N.m

7 Lower the vehi cle to the ground.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 34

7E4 – 34

3.7 Output Drive Flange and Oil Seal

ATTENTION

The following fasteners MU ST be replaced when performing these operatio ns:

 Output flange retaining nut.

 Front coupling to transmission output flange fastener s as noted in the text.

A number of different methods of attaching

the front coupling to the transmission output

flange can be noted:

• Hexagon headed bolts into threaded

flange holes. With this method, the output

flange threads are of the 'Spiralock' form

that can only be loosened/tightened a

maximum of ten times. Because of the

safety factor involved, if the complete

vehicle service history is not known, then

both the flange and the bolts MUST be

replaced on reassembly.

• Studs installed into the transmission

output flange facing rearward, with the

flange being secured by nuts.

• Torx headed bo lts and nu ts. Figu re 7E4–56

shows this method.

LT Section No. – 04-200

Remove

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information in this Service Information

for the location of recommended lifting and supp ort points.

2 Loosen, then remove the three front propeller shaft

coupling (1) to output flange bolts (2), nuts (3) and

washers (4).

3 Push the front propeller shaft to the rear of the vehicle

to release the front propeller shaft couplin g from the

transmission output shaft spigot.

Figure 7E4 – 41

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 35

7E4 – 35

4 Use tie wire (2) or similar to support the front propeller

shaft (1) to a convenient underbody point, such as the

shift lever (3).

Figure 7E4 – 42

5 Install holding tool DT-47735 (also released as

KM620-1A) to the transmission output flange, using

three, fully threaded, M10 bo lts and nuts.

NOTE

Using smaller OD bolts and nuts will not impact

on the output flange 'Spiralock' thread forms, if

used.

If Park is selected to lock the output shaft,

DO NOT use impact equipment to loosen the

flange nut.

6 Insert a suitable length of pipe (1) over the tang of the

installed tool for leverage, then remove the output

flange retaining nut, using a commercia lly available,

30 mm deep socket and socket bar (2).

7 Remove holding tool DT-47735 (or KM 620-1A) from

the output flange. Figure 7E4 – 43

8 Remove the dished washer (4), then the output flange

(2) and O-ring seal (3), from the transmission output

shaft.

9 Remove the O-ring seal (3) from the output flange(2).

NOTE

• Discard parts ‘3’, ‘4’ and ‘5’, as they are

included in the one service kit. Refer to the

current release of Partfinder™ for the correct

part number.

• The output shaft assembly retainer (1) can

only be removed after the oil seal is removed

(Step 11). This retainer is als o incl uded in th e

service kit.

Figure 7E4 – 44

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 36

7E4 – 36

10 Remove the output flange oil seal (1), using seal

remover J 23129 and slide hammer J 6125-1B or seal

remover E308 (or commercial equivalent).

11 Using suitable snap ring pliers, remove the output

shaft assembly retainer ('1' in Figure 7E4 – 46), then

discard the removed retainer.

Figure 7E4 – 45

Reinstall

1 Install a NEW output shaft assembl y retaine r (' 1' in

Figure 7E4 – 70). Position the retainer over the end of

the output shaft splines. The retainer will be installed

to the correct depth when the output flange is install ed.

2 Lubricate the l ips of a NEW oil seal (1) then install

onto the installation tool J 44765.

NOTE

Fitting the seal onto the installation tool before

installation will prevent seal lip damage.

3 Install the NEW oil seal (1) into the transmission

extension housing, using tool J 44765 and a hammer.

Figure 7E4 – 46

4 Clean all traces of thread sealant from the

transmission output shaft threads, using a wire brush.

5 Lubricate a NEW O-ring seal (3) with transmission

fluid, then install into the output flange (2).

6 Install the output flange (2) and O-ring (3) assembly

over the splines of the transmission output shaft.

NOTE

Refer to the 'Caution' stateme nt at the beginning

of this Service operation to determine whether

the flange is to be replaced or not.

7 Install a NEW dished thrust washer (4), with the curve

facing outward.

8 Install a NEW output flange retaining nut (5).

NOTE

A new nut has micro-encapsulation applied to

the threads. Figure 7E4 – 47

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 37

7E4 – 37

9 Install holding tool DT-47735 (also released as

KM620-1A) to the transmission output flange, using

three, fully threaded, M10 bo lts and nuts.

NOTE

Using smaller OD bolts and nuts will not impact

on the output flange 'Spiralock' thread forms, if

used.

If Park is selected to lock the output shaft,

DO NOT use impact equipment to tighten the

flange nut.

10 Insert a suitable length of pipe (1) over the tang of the

installed tool for leverage, then instal l the NEW output

flange retaining nut, using a commercia lly available,

30 mm deep socket and socket bar (2). T ighten to the

correct torque specification.

Transmission output flange

retaining nut torque specification .........................60 N.m

11 Remove holding tool DT-47735 (or KM620-1A) from

the output flange.

Figure 7E4 – 48

12 Remove the tie wire supporting the front propeller

shaft.

13 Smear NLGI No. 2 lithium soap based EP grease with

molybdenum disulphide such as Shell Retinax HDX2

grease, BP Energrease LMS-EP 23 or equivalent over

the transmission output shaft spigot.

14 Install the propeller shaft front coupling to the output

flange.

NOTE

Refer to the 'Caution' stateme nt at the beginning

of this service operation to determine whether

the bolts are to be replaced or not.

15 Install fasteners to secure the coupling to the

transmission output flange. Tighten the bolts to the

correct torque specification.

Front propeller shaft couplin g nuts

or bolts and nuts torque specification.................115 N.m Figure 7E4 – 49

Front coupling bolts to ‘Spiralock’

flange threads torque specification ......................85 N.m

16 Check the transmission fluid level, topping up as required. Refer to 2.1 Transmission Fluid Check, in this Section.

17 Check for transmission fluid leaks.

18 Lower vehicle to the ground.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 38

7E4 – 38

3.8 Extension Housing

LT Section No. – 04-200

Remove

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information in this Service Information

for the location of recommended lifting and supp ort points.

2 Remove the transmission o utput flang e (2), refer to

3.7 Output Drive Flange and Oil Seal, in this Section

for the necessary procedure.

NOTE

• If the extension housing oil seal is not

removed, the output shaft assembly retainer

(1) will be withdrawn, when the extension

housing is removed.

• Discard parts ‘1’, ‘3’, ‘4’ and ‘5’, as they are

included in the one service kit. Refer to the

current release of Partfinder™ for the correct

part number.

3 Remove the transmission mo unt. Refer to

3.6 Transmission Mount and Mount Plate, in this

Section.

Figure 7E4 – 50

4 Place an oil drain pan under the rear of the

transmission.

5 Remove the extension housing bolts (35).

6 Remove the ex tension housing (27) and sealing

gasket (25).

NOTE

• In not removed previously, the output shaft

retainer ('1' in Figure 7E4 – 50), will slide

from the output shaft during the extension

housing removal operation.

7 Do not lose the selective thrust washer (22) and

bearing when the extension housing is removed.

Figure 7E4 – 51

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 39

7E4 – 39

Reinstall

1 Smear the selective washer (22) and thrust bearing (23) with petroleum jelly (e.g. Vaseline™ or equivalent), install

‘22’ then ‘23’ over the output shaft.

NOTE

The selection of the thrust washer (22) thickness

is dependent upon the relationship of the

transmission case end machined surface to the

face of the output shaft. This dimension is not

affected by an extension h ousing replacement.

2 Reinstall the extension housing (27) and the sealing

gasket (25) to the rear of the transmission.

NOTE

If the sealing gasket is undamaged, then it may

be reused.

3 Reinstall the e xtension housing retaining bolts (35)

and tighten to the correct torque specification.

Extension housing retaining

bolt torque specification.......................................22 N.m

Figure 7E4 – 52

4 Reinstall the transmission rear mount and crossmember. Refer to 3.6 Transmission Mount and Mount Plate, in this

Section.

5 Install a NEW drive flange oil seal, then reinstall the drive flange. Refer to 3.7 Output Drive Flange and Oil Seal, in

this Section.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 40

7E4 – 40

3.9 Transmission Internal Electrical Harness

Replace

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Release the transmissio n wiring harness connector (1)

by rotating the locking sleeve (2) in a counter-

clockwise direction (to the left).

3 Pull on the connector to disconnect from the

transmission internal harness connector.

Figure 7E4 – 53

4 Remove the transmission fluid pan and filter. Refer to

3.1 Fluid Change and Filter Replace, in this Section.

5 Lift the locking latch an d disconnect the connectors

from items 1 – 8.

Legend:

1 Output Speed Sensor

2 1-2 Shift Solenoid

3 Input Speed Sensor

4 Pressure Control Solenoid

5 Torque Converter Clutch (TCC) PWM Solenoid

6 Manual Shaft Shift Position Switch

7 4-5 Shift Solenoid

8 2-3 Shift Solenoid

Figure 7E4 – 54

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 41

7E4 – 41

6 Remove the internal wiring harness connector retainer

(2) from the connector (1).

7 Gently tap on the en d of the wirin g harness connector

with a plastic hammer to dislodge the O-ring seal.

Figure 7E4 – 55

8 Remove the internal wiring harness (55) from the

transmission.

9 Only remove the O-rings from the wiring harness

connector, if they are worn or damaged.

Figure 7E4 – 56

The installation process is the reverse to removal, except for the follo wing:

10 If removed, apply transmission fluid to NEW O-ring

seals and install to the internal wiring harness

connector.

11 Install the wiring harness connector to the

transmission case, aligning the lug on the connector

body with the gap in the trans m ission case casting.

12 Secure the wiring harness connector (1) to the

transmission case, with the retainer (2), noting the

orientation.

Figure 7E4 – 57

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 42

7E4 – 42

13 Reinstall each of the connectors to parts 1 – 8,

checking that each connector security latch is

engaged.

Legend:

1 Output Speed Sensor

2 1-2 Shift Solenoid

3 Input Speed Sensor

4 Pressure Control Solenoid

5 Torque Converter Clutch (TCC) PWM Solenoid

6 Manual Shaft Shift Position Switch

7 4-5 Shift Solenoid

8 2-3 Shift Solenoid

Figure 7E4 – 58

14 Install a NEW transmission fluid filter and the fluid pa n

to the transmission, reusing the original pan gasket

seal, if undamaged.

Refer to 3.1 Fluid Change and F ilter Replace, in this

Section.

15 Reinstall the transmission wiring harness connector

(1) to the transmission internal wiring harnes s

connector and secure by rotating the locking sleeve

(2) in a clockwise direction.

Figure 7E4 – 59

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 43

7E4 – 43

3.10 Manual Shaft Oil Seal

NOTE

This procedure requires the use of special tool

No. AU 583. Should this tool not be available, the

seal can still be replaced but involves the removal

of the selector shaft from the transmission case.

Refer to 3.11 Manual Shaft Position Switch, in

this Section for the procedure.

LT Section No. – 04-200

Replace

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information in this Service Information

for the location of recommended lifting and supp ort points.

2 While holding the transmission shift lever (2) with an

adjustable wrench, remove the nut (1) securing the

shift lever (2) to the transmission manual shift shaft.

3 Disconnect the shift lever from the transmission

manual shift shaft.

Figure 7E4 – 60

4 Assemble the remover nut (Tool No. AU 583-4) with

the threaded section closest to the hexago nal head of

the seal remover AU 583-3. Install the nut up to the

hexagonal e nd.

5 Install the pre-assembled remover (Tool Nos. AU 583-

3 and AU 583-4) over the manual shaft (1) a nd

engage the tapered thread en d of the seal re mover

into the seal. Tighten the seal remover until the tool

thread grips the outer shell of the seal.

NOTE

Do not overtighten the seal remover into the

seal.

Figure 7E4 – 61

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 44

7E4 – 44

6 While holding the seal remover (AU 583-3) with a

suitable spanner, use a second spann er to screw the

remover nut (AU 583-4) up to the transmissio n case.

7 Continue tightening the remover nut until the seal is

removed into the remover nut cavity.

8 Discard the removed se al.

Figure 7E4 – 62

9 Pre-assemble the seal protector sleeve (AU 583-1)

into one of the plastic seal installers (AU 583-2), as

shown in the sectioned view.

10 Lubricate the seal lip of a new seal (1) with Dexron® III

automatic transmission fluid, then install it (wit h the

steel seal casing facing the installer) over the seal

protector sleeve (AU 583-1).

11 Install the seal protector sleeve (AU 583- 1), seal (1)

and seal installer (AU 583-2), over the manu al shaft

and up to the transmission case.

NOTE

If the seal protector sleeve (AU 583-1) jams on

the manual shaft, then the shaft will be burred

over the flats that locate the shift lever. Use a

fine file to remove burrs, then proceed.

12 Install the second plastic seal installer over the manual

shaft until it seats against the first installer.

NOTE

The two plastic seal installers (AU 583-2) are

required, because of the restricted space

between the end of the manual shaft and the

floor pan.

Figure 7E4 – 63

13 Install the manual shaft lever retaining nut (2) and tighte n it to install the seal fully into place in the transmission

case.

14 Remove installer tools, AU 583-2 (two pieces) and seal protector sleeve AU 583- 1 from the manual shaft.

15 Reinstall the shift shaft lever to the transmission manual shaft, then install the retaining nut.

16 While holding the manual shift lever with an adjustable wrench, tighten the retaining nut to the correct torque

specification.

Manual shift shaft lever retaining

nut torque specification........................................ 12 N.m

17 Check and adjust the shift control linkage. Refer to 3.2 Selector Linkage, Adjust, in this Section.

18 Check and top up transmission fluid level as required. Refer to 2.1 Transmission Flu id Check, in this Section.

19 Inspect for transmission fluid leaks.

20 Lower the vehicle to the ground.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 45

7E4 – 45

3.11 Manual Shaft Position Switch

LT Section No. – 04-170

Remove

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Mark the relationship of the transmissi on mount

crossmember to each body side rail (‘A’) with a felt

tipped pen or similar.

NOTE

This is necessary to maintain alignment on

reassembly.

3 Position a suitable transm issio n jack under the

transmission rear mount crossmember.

4 Remove the four bolts secur in g the transmission

mount crossmember to the body side rails.

Figure 7E4 – 64

5 While holding the shift lever with an adjustable

wrench, remove the nut (1) securing the transmission

shift lever (2) to the transmission manual shift shaft.

6 Disconnect the shift lever from the transmission

manual shift shaft.

7 Remove the transmission fluid pan and filter. Refer to

3.1 Fluid Change and Filter Replace, in this Section.

8 Remove the electrical connector from the manual shift

shaft position switch, after releasing the connector

security latch.

Figure 7E4 – 65

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 46

7E4 – 46

9 Using a suitable pin punch (2), remove the roll pin ( 1)

securing the manual shaft position switch to the

manual shaft.

Figure 7E4 – 66

10 Remove the manual shaft detent spring (1) by

removing the two bolts (2).

Figure 7E4 – 67

11 Lower the rear of the transmission, enough to provide

clearance bet ween the manu al shift shaft (606) and

the vehicle floor pan.

12 Remove the manual shift shaft (606) from the

transmission case, enough to allow removal of the

shift shaft position switch and associated components.

13 Remove the manual shift shaft position switch (602),

manual shift shaft detent lever (600) and the park pawl

actuator (613), as an assembly.

14 Disassemble the manual shift shaft position switch

(602) from the manual shift shaft detent lever (600).

Figure 7E4 – 68

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 47

7E4 – 47

Reinstall

1 Refer to Figure 7E4 – 68. Reinstall the manual shift shaft position switch (602), the manual shift shaft detent

lever (600) and the park pawl actuator (613) as an assem bl y.

2 Align the manu al shift shaft detent lever (600) shaft hole with the case, then fully insert the manual shift shaft (606)

into the transmission case.

3 Raise the rear of the transmission and align the crossmember position marks, made before removal.

4 Reinstall the fo ur bolts securing the crossmember to the body side rails and tighten to the correct torque

specification. Remove the transmission jack.

Transmission crossmember to side

rail bolt torque specification..................................58 N.m

5 Reinstall the manual shift shaft detent spring (1).

6 Reinstall the two control valve body and manual sh ift

shaft detent spring retaining bolts(2). Do not fully

tighten at this time.

Figure 7E4 – 69

7 Confirm that the manual shift shaft detent pin (2) is

engaged with the manual shaft link (1).

8 Confirm also, that the detent spring roll er (4) is

correctly engaged with the manual shift shaft

switch (3).

Figure 7E4 – 70

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 48

7E4 – 48

9 Using a suitable size pin punch, align the pin hol e in

the manual shift position switch with the hole in the

manual shift shaft.

NOTE

With the pin punch inserted in the manual shift

shaft, rotate the manual shift shaft detent

lever (600) and check that the park pawl

mechanism engages correctly.

10 Using a suitable size pin pu nch (2), install a NEW roll

pin (1) to secure the manual shift shaft position switch

to the manual shift shaft.

11 Reinstall the electrical connector to the manual shift

shaft position switch and check that the secu rity latch

is fully engaged.

Figure 7E4 – 71

12 Install an 0.8 mm spacer ('A') (e.g. feeler gauges)

between the manual shaft detent lever (600) and the

manual shaft detent spring (52).

13 Tighten the two detent spring retaini ng bolts to the

correct torque specification.

Manual shaft detent spring

bolt torque specification.......................................11 N.m

14 Remove the spacer.

15 Install a NEW transmission fluid filter, then the

transmission fluid pan to the transmission, reusin g the

original pan gasket seal, if undamaged.

Refer to 3.1 Fluid Change and F ilter Replace, in this

Section.

Figure 7E4 – 72

16 If the manual shift shaft oil seal was removed, install a NEW oil seal. Refer to 3.10 Manual Shaft Oil Seal, in this

Section.

17 Reinstall the manual shift shaft select lever to the manual shift shaft.

18 Reinstall the manual sh aft shift select lever retaining nut then, while holding the lever with an adjustable wrench,

tighten the nut to the correct torque specification.

Manual shift shaft lever retaining

nut torque specification........................................ 12 N.m

19 Check and adjust the shift control linkage as required. Refer to 3.2 Selector Linkage – RWD Models, Adjust, in this

Section.

20 Check and top up transmission fluid level as required. Refer to 2.1 Transmission Flu id Check, in this Section.

21 Inspect for transmission fluid leaks.

22 Lower the vehicle to the ground.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 49

7E4 – 49

3.12 Input Speed Sensor

Replace

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the transmission fluid pan and fluid filter. Refer to 3.1 Fluid Chan ge and Filter Replace, in this Section.

3 Release the wiring harness connector security latch,

then disconnect the connector (1) from the input speed

sensor (2).

4 Remove the input speed sensor retaining screw (3),

using a 10 mm socket and suitable equipment.

Figure 7E4 – 73

5 Remove the input speed sensor (1) from the

transmission case.

6 Inspect the input speed sensor for the following:

a A damaged or missing magnet.

b Damaged housing.

c Bent or missing electrical terminals.

d Metal contamination adhered to the magnet.

Figure 7E4 – 74

7 After reinstalling the input spe ed sensor, install the retaining screw, tightening to the correct torque specification.

Input speed sensor retaining

screw torque specification....................................11 N.m

8 Reinstall the e lectrical connector to the input speed sensor ensuring that the security latch is fully installed.

9 Install a NEW transmission flu id filter, then the transmission fluid pan to the transmission, reusing the original pan

gasket seal, if undamaged. Refer to 3.1 Fluid Chang e and Filter Replace, in this Section.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 50

7E4 – 50

3.13 Output Speed Sensor

Replace

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the transmission fluid pan and fluid filter. Refer to 3.1 Fluid Chan ge and Filter Replace, in this Section.

3 Release the wiring harness connector security latch,

the disconnect the connector (3) from the output

speed sensor (2).

4 Using a 10 mm socket and suitable equipment,

remove the output speed sensor retaining screw (1).

Figure 7E4 – 75

5 Remove the output speed sensor (2) from the

transmission case.

6 Inspect the output spee d sensor for the following:

a A damaged or missing magnet.

b Damaged housing.

c Bent or missing electrical terminals.

d Metal contamination adhered to the magnet.

Figure 7E4 – 76

7 After reinstalling the output speed se nsor, install the retaining screw and tighten to the correct torque specification.

Output speed sensor retaining

screw torque specification....................................11 N.m

8 Reinstall the e lectrical connector to the output speed sensor ensuring that the security latch is fully installed.

9 Install the fluid filter and the fluid pan to the transmission, reusing the original pa n gasket seal, if undamaged. Refer

to 3.1 Fluid Change and Filter Replace, in this Section.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 51

7E4 – 51

3.14 1-2 Shift Solenoid

Replace

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the transmission fluid pan and fluid filter. Refer to 3.1 Fluid Chan ge and Filter Replace, in this Section.

3 Release the wiring harness connector security latch,

then disconnect the connector (1) from the 1-2 shift

solenoid (2).

Figure 7E4 – 77

Wear eye protection to prevent potential

injury.

4 Using a small bladed screwdriver or a hooked piece of

wire, remove the 1-2 shift solenoid retainer (1) from

the control valve body.

5 Twist and pull on the 1-2 solenoid to remove it from

the control valve body.

Figure 7E4 – 78

6 Remove the 1- 2 shift solenoid (1) from the control

valve body.

Reinstallation of the 1-2 shift solenoid is the reverse to

removal, taking note of the following items:

Wear eye protection to prevent potential

injury.

7 After installing the 1-2 shift solenoid into the control

valve body, install the retainer, to secure.

8 After installing the electrical connector, check that the

connector security latch is secure.

9 Reinstall the fluid filter and fluid pan.

Refer to 3.1 Fluid Change and F ilter Replace, in this

Section.

Figure 7E4 – 79

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 52

7E4 – 52

3.15 2-3 Shift Solenoid

Replace

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the transmission fluid pan and fluid filter. Refer to 3.1 Fluid Chan ge and Filter Replace, in this Section.

3 Release the wiring harness connector security latch,

the disconnect the connector (1) from the 2-3 shift

solenoid (2).

Figure 7E4 – 80

Wear eye protection to prevent potential

injury.

4 Using a small bladed screwdriver or a hooked piece of

wire, remove the 2-3 shift solenoid retainer (1) from

the control valve body.

5 Twist and pull on the 2-3 solenoid to remove it from

the control valve body.

Figure 7E4 – 81

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 53

7E4 – 53

6 Remove the 2- 3 shift solenoid (1) from the control

valve body.

Reinstallation of the 2-3 shift solenoid is the reverse to

removal, taking note of the following items:

Wear eye protection to prevent potential

injury.

7 Reinstall the 2-3 shift solenoid into the control valve

body, then install the retainer, to secure.

8 Reinstall the e lectrical connector and check that the

connector security latch is secure.

9 Reinstall the fluid filter and fluid pan.

Refer to 3.1 Fluid Change and F ilter Replace, in this

Section.

Figure 7E4 – 82

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 54

7E4 – 54

3.16 4-5 Shift Solenoid

Replace

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the transmission fluid pan and fluid filter. Refer to 3.1 Fluid Chan ge and Filter Replace, in this Section.

3 Release the wiring harness connector security latch,

the disconnect the connector (1) from the 4-5 shift

solenoid (2).

Figure 7E4 – 83

Wear eye protection to prevent potential

injury.

4 Using a small bladed screwdriver or a hooked piece of

wire, remove the 4-5 shift solenoid retainer (1) from

the control valve body.

5 Twist and pull on the 4-5 solenoid to remove it from

the control valve body.

Figure 7E4 – 84

6 Remove the 2- 3 shift solenoid (1) from the control

valve body.

Reinstallation of the 4-5 shift solenoid is the reverse to

removal, taking note of the following items:

Wear eye protection to prevent potential

injury.

7 After installing the 2-3 shift solenoid into the control

valve body, install the retainer, to secure.

8 After installing the electrical connector, check that the

connector security latch is secure.

9 Reinstall the fluid filter and fluid pan.

Refer to 3.1 Fluid Change and F ilter Replace, in this

Section.

Figure 7E4 – 85

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 55

7E4 – 55

3.17 Pressure Control Solenoid

Replace

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the transmission fluid pan and fluid filter. Refer to 3.1 Fluid Chan ge and Filter Replace, in this Section.

3 Release the wiring harness connector security latch,

the disconnect the connector (2) from the pressure

control solenoid (PCS) (1).

Figure 7E4 – 86

Wear eye protection to prevent potential

injury.

4 Using a small bladed screwdriver or a hooked piece of

wire, remove the pressure control solenoid retainer (1)

from the control valve body.

Figure 7E4 – 87

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 56

7E4 – 56

5 Twist the pressure control soleno id (1) through 90° to

provide enough clearance, then pull to remove it from

the control valve body.

Figure 7E4 – 88

Reinstallation of the pressur e control solenoid is the reverse to removal, taking note of the following items:

6 Reinstall the pressure control solenoid to the control

valve body, then rotate the solenoid until the tang (1)

on the solenoid body aligns with the slot (2) in the

control valve body, as shown.

Wear eye protection to prevent potential

injury.

7 Install the retainer to secure t he solenoid.

8 After installing the electrical connector, check that the

connector security latch is secure.

9 Reinstall the fluid filter and fluid pan.

Refer to 3.1 Fluid Change and F ilter Replace, in this

Section.

Figure 7E4 – 89

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 57

7E4 – 57

3.18 Torque Converter Clutch (TCC) PWM

Solenoid

Replace

1 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the transmission fluid pan and fluid filter. Refer to 3.1 Fluid Chan ge and Filter Replace, in this Section.

3 Release the wiring harness connector security latch,

the disconnect the connector (1) from the torque

converter clutch PWM solenoid.

NOTE

There is insufficient clearance to remove the

TCC PWM solenoid with the control valve body

fully installed. Compl ete removal however, is not

necessary.

DO NOT loosen the two TX-30 Torx screws

(3).

4 Loosen the eight, E8 Torx headed control valve body

bolts (2).

5 Loosen the one detent spring retaining bolt (4).

Figure 7E4 – 90

• Hold the solenoid in place while the

retaining clip is removed, as the spring

loaded TCC Regulator Valve will cause

the solenoid to be ejected from the

control valve body accumulator

assembly.

• Wear eye protection to prevent potential

injury.

6 Using a small bladed screwdriver or a hooked piece of

wire, remove the pressure control solenoid retainer (1)

from the control valve body.

7 Release the sp ring pressure.

Figure 7E4 – 91

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 58

7E4 – 58

8 If necessary, loosen the c ontrol valve body bolts,

lowering the valve body until sufficient clearance is

gained to allow solen oid removal.

9 Remove the TCC PW M solenoid from the control

valve body assembly.

Reinstallation of the TCC PWM solenoid is the reverse to

removal, taking note of the following items:

10 Reinstall the TCC PWM solenoid to the Control Valve

Body Accumulator assembly then, while holding the

solenoid in against spring force, reinstall the retainer to

secure the solenoid (see Figur e 7E4 – 120).

11 Reinstall the wiring harness connector to the TCC

PWM solenoid then check that the connector security

latch is secure.

Figure 7E4 – 92

12 Gradually tighten the eight control valve body bolts but

do not fully tighten, out of sequence.

13 Finally tighten the eight control valve body and

accumulator to case bolts in the correct sequence as

shown and to the correct torque specificatio n.

Control valve body assembly

to transmission case bolt

torque specification..............................................11 N.m

Figure 7E7 – 93

14 Install an 0.8 mm spacer ('A') (e.g. feeler gauges)

between the manual shaft detent lever (600) and the

manual shaft detent spring (52).

15 Tighten the loosened detent spring retaining bolt to the

correct torque specification.

Manual shaft detent spring

bolt torque specification.......................................11 N.m

16 Remove the spacer.

17 Reinstall the fluid filter and fluid pan.

Refer to 3.1 Fluid Change and F ilter Replace, in this

Section.

Figure 7E4 – 94

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 59

7E4 – 59

3.19 Solenoid Leak Testing

• This procedure only tests ON/OFF

solenoids such as the 1–2, 2–3 and 4–5

shift solenoid valves.

• Visually inspect the physical condition of

the solenoid valve before testing. Also

check the O-rings before and after testing

to ensure that they are not cut or

damaged.

1 Remove the shift solenoid valve from the control valve body. Refer to 3.14 1-2 Shift Solenoid,

3.15 2-3 Shift Solenoid, or 3.16 4-5 Shift Solenoi d, in this Section.

2 Install the shift solenoid valve (1) to be tested, into

bore number 5 of Tool J 44246 T est Block. Secure

with the original retaining clip ( 2).

Figure 7E4 – 95

3 Connect the solen oid test harness (1) supplied with

the J 44246 Solenoid Testing Kit to the solenoid (2).

Do not use air pressure exceeding 800 kPa.

Excessive pressure will not allow the

solenoid ball check valve to seat properly.

Recommended air pressu re is 350 kPa.

4 Apply compressed air (3) to the test kit block, as

shown.

5 Connect the test harness to the 12 vo lt battery

terminals.

6 Check that the solenoid is operating electrically by

listening for an audible clicking noise as the test

harness makes and breaks voltage contact.

NOTE

• All solenoids need to be ener gised to seal.

• A small amount of air leakage is normal

(± 21 kPa). Figure 7E4 – 96

7 Observe the air flow through the solenoid. The flow will either completely or nearly stop, when the sole noid is

energised. Replace any sol en oid where an obvious air leak is observed when the solenoid is energ ised.

NOTE

Inspect the O-rings after testing to ensure that

they are not cut or damaged.

8 Reinstall the solenoid valve to the control valve body. Ref er to 3.14 1-2 Shift Solenoid, 3.15 2-3 Shift Solenoid, or

3.16 4-5 Shift Solenoid, in this Section.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 60

7E4 – 60

3.20 Control Valve Body and Accumulator

Assembly

The control valve body a nd accumulator assembly is not serviced. Therefore, if replacement is required, the complete

transmission must be changed. Refer to 3.22 5L40-E Automatic Transmission, in this Section.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 61

7E4 – 61

3.21 Transmission Control Module (TCM)

LT Section No. – 04-999

Remove

1 Ignition OFF.

2 Remove left hand front hin ge pillar trim assembly. Refer to 2.8 Hinge Pillar Trim Assembly, Remove, in

Section 1A8 Headlining & Interior Trim.

3 Prise the TCM free from the holder plastic cli ps. F inger tip pressure is only required.

4 Push the TCM up ward, then pull outward and down at the lower edge, freeing the wiring harness and connector

from the holder.

Twisting or tilting the transmission control

module electrical connector while

disconnecting, may result in bent or

misaligned electrical terminal pins.

5 Unlock the transmission control module electrical

connector by pulling the retainer (2) out from the

electrical connector (1).

6 Carefully pull the electrical connector (1) straight out,

from the TCM.

Figure 7E4 – 97

Reinstall

Twisting or tilting the transmission control

module electrical connector while

disconnecting, may result in bent or

misaligned electrical terminal pins.

1 Carefully connect the transmission control module

electrical connector (1) to the TCM.

2 Lock the transmission control module electrical

connector securely to the TCM by pushing the retainer

(2) into the electrical connector (1) until ful ly seated.

3 Reinstall the TCM to the mounting bracket, in the

reverse to removal, ensuring that the T CM holding

clips are all engaged.

NOTE

If the TCM is difficult to secure in the holding

clips, check that the wiring harness is not fouli ng

the TCM connector on the inside of the mountin g

bracket.

Figure 7E4 – 98

4 Reinstall the l eft hand front hinge pillar trim assembly. Refer to 2.8 Hinge Pillar trim Assembly, Reinstall, in

Section 1A8 Headlining & Interior Trim..

5 The transmission control module must be programmed with the correct software/calibration.

Refer to TCM Programming Procedure, in this Section.

Techline

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 62

7E4 – 62

TCM Programming Procedure

1 The transmission contro l module (TCM) must be programmed with the correct software/calibration. Ensure that the

following conditions exist bef ore starting the TCM programming procedur e:

a The battery is fully charged.

b The TE CH 2 cable connection at the data link connector (DLC) is secure.

c The ignition switch is in the ON position.

2 Program the TCM usin g the latest software for the vehicle. Refer to the current release of TIS for the latest software

and Section 0C Tech 2 for user instructions.

3 If the TCM fails to program, procee d as follows:

a Ensure that the TCM connection is OK.

b Check that TECH 2 is programmed with the latest software version.

c Attempt to re-program the TCM. If the TCM still cannot be programmed properly, replace the TCM.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 63

7E4 – 63

3.22 5L40-E Automatic Transmission

ATTENTION

The following fasteners MUST be replaced when performin g these operations:

 Torque converter to flexplate attaching bolts.

 Front propeller shaft fasteners, as noted in th e text.

LT Section No. – 04-200

Remove

A number of different methods of attaching

the front coupling to the transmission output

flange can be noted:

• Hexagon headed bolts into threaded

flange holes. With this method, the output

flange threads are of the 'Spiralock' form

that can only be loosened/tightened a

maximum of ten times. Because of the

safety factor involved, if the complete

vehicle service history is not known, then

both the flange and the bolts MUST be

replaced on reassembly.

• Studs installed into the transmission

output flange facing rearward, with the

flange being secured by nuts.

• Hexagon headed bolts and nuts. Figure

7E4–116 shows this method.

NOTE

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Cautions and Notes,

5 Battery Disconnection Procedures before

disconnecting the batter y.

1 Disconnect the negative battery cable.

2 Drain the engin e coolant into a clean container. Depending on the age of the coolant it may be able to be used

again. Refer to Section 6B1 Engine Cooling – V6 Engine for further information.

3 Remove the engine thermostat housing. This is necessary to enable access to the upper transmission to engine

attaching bolts. Refer to Section 6B1 Engine Cooling – V6 Engine.

4 Raise the vehicle and support in a safe manner. Refer to Section 0A General Information in this Service Information

for the location of recommended lifting and supp ort points.

5 Drain the transmission fluid. Refer to 3.1 Fluid Change and/or F ilter Replace, in this Section.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 64

7E4 – 64

6 While holding the transmission manual shaft lever (2)

with an adjustable wrench, loosen then remove the

transmission manual shaft lever retaining nut (1).

7 Disconnect the shift lever from the manual shaft.

8 Place the transm ission in the Neutral range.

Figure 7E4 – 99

9 Remove both exhaust pi pes and catalytic converters, back to the intermediate pipe flanges.

Refer to Section 8B Exhaust System.

NOTE

While this operation is not essential, removal of

the exhaust pipes does provide additional space

around the transmission and will remove the

possibility of accidental damage to the oxygen

sensors.

10 Using a felt tipped pen or similar, mark the relationship

of the front coupling to the transmission output shaft

flange (A).

11 Loosen, then remove the three front propeller shaft

coupling (1) to output flange bolts (2) and nuts (3).

12 Push the front propeller shaft to the rear of the vehicle

to release the front propeller shaft couplin g from the

transmission output shaft spigot.

Figure 7E4 – 100

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 65

7E4 – 65

13 Use tie wire (2) or similar to support the front prop eller

shaft (1) to a convenient underbody point.

Figure 7E4 – 101

14 As access to the transmission wiring harness cable ties around the transmission is restricted, it is recommended

that the transmission wiring harness be disconnected from the transmission control module (TCM) and removed

with the transmission. Refer to 3.21 Transmission Control Module, in this Section.

15 Remove the starter motor.

Refer to Section 6D1-2 Starting System – V6.

16 Mark the torque converter to flexplate orientation to

ensure correct reinstallation al ignment.

17 Rotate the engine harmonic bala ncer in a clockwise

direction ONLY, to align a torque converter bolt with

the starter motor opening.

18 Remove and discard the torqu e converter b ol ts, as

they MUST be replaced on reassembly.

19 Repeat Steps 15 and 16 for the remaini ng two t orque

converter bolts.

Figure 7E4 – 102

20 Place an oil drain pan under the transmission fluid

cooler pipes.

21 Remove the nut (1) securing the transmission cooler

pipe bracket (2) to the alternator mounting bracket

stud.

Figure 7E4 – 103

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 66

7E4 – 66

22 Remove the bolt (2) securing the transmission fluid

cooler pipes bracket (3) to the transmission case.

23 Remove the transmission fluid cool er pipes from the

transmission.

24 Remove the two O-rings (1) and discard, as they must

be replaced on assembly.

25 Plug all open ends to stop fluid loss and foreign matter

entry.

Figure 7E4 – 104

26 Check that one of the fluid cooler flexible lines has a

white tag attached and that the mating transmission

cooler pipe has a similar tag. If these have been

removed, apply adhesive tap e to one pair of

pipes/lines to ensure correct reassembly.

27 Using disconnect Tool No. AU 525, disc onnect each

fluid cooler flexible line quick connect fitting (1) from

each pipe.

NOTE

The fluid cooler flexible lines are permanently

attached to the radiator fluid cooler pipes.

28 Plug all open ends to prevent fluid loss an d foreign

matter entry.

29 Remove the transmission cooler pipes from the

vehicle.

30 Position a suitable transmission jack under the

transmission fluid pan. Figure 7E4 – 105

31 Mark the relationship of the transmission mount

crossmember to each body side rail (‘A’) with a felt

tipped pen or similar.

NOTE

This is necessary to maintain alignment on

reassembly.

32 Remove the four bolts (1) securing the transmission

mount crossmember to the body side rails.

33 Remove the two nuts (2) securing the transmission

mount to the crossmember.

34 Remove the crossmember from the vehicle. Figure 5A – 106

35 Lower the engine and transmission enough to gain access to the wiring har ness securing clips (1 and 2).

36 Prise the two ‘fir tree’ wiring harness retaining clips (1 and 2) free from their locations.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 67

7E4 – 67

Figure 7E4 – 107

37 Remove the close-out cover screw (4), then remove

the cover.

38 Lower the engine and transmi ssion enough to gain

access to the four upper transmission to engine

mounting bolts (3).

39 Remove the four upper transmission to engine

mounting bolts (3).

40 Remove the remaining six l ower transmission to

engine mounting bolts (‘1’ and ‘2’).

NOTE

Three bolts are hidden from view.

41 Pull the transmission rearwards, enough to free the

transmission from the two engine dowels.

Ensure clearance is maintained between the

transmission and the following:

• The catalytic converters and oxygen

sensors [if the exhaust pipes were not

removed (Step 9)].

• Wiring harnesses.

• The propeller shaft.

42 Carefully lower the transmissi on from the vehicle.

Figure 7E4 – 108

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 68

7E4 – 68

Reinstall

The reinstallation process is the reverse to the removal procedure except fort the items detailed here.

1 Lubricate the torque converter spigot with an NLGI No. 2 lithium soap bas ed EP grease with molybdenum

disulphide, such as Shell Reti nax HDX2 grease or BP Energrease LMS-EP 23 (or equivalent).

2 After carefully r einsta lling the transmission, using a transmission jack, align the engine do wels with the

transmission and fully install t o the rear of th e engine.

3 Reinstall the six lower bolts (‘1’ and ‘2’), then tighten to

the correct torque specification.

Transmission to engine

bolt torque specification.......................................60 N.m

4 If necessary lower transmission at the rear to gain

access to the upper transmission to engine fasteners.

5 Reinstall the fo ur upper transmission to engine bolts

(3) and tighten to the correct torque specificat ion.

Transmission to engine

bolt torque specification.......................................60 N.m

6 Reinstall the wiring harness retaining clips.

7 Reinstall the close-out cover and secure with the

retaining screw (4), tightening to the correct torque

specification.

Close-out cover retaining

screw torque specification....................................14 N.m

8 Reinstall the engine thermostat housing and replenish

the engine coolant.

Refer to Section 6B1 Engine Coolin g – V6 Engine.

Figure 7E4 – 109

9 Raise the transmission, then reinstall the rear mount crossmember.

Refer to 3.6 Transmission Mount and Mount Plate, Reinstall, in this Section.

10 Reinstall the transmission flu id cooler pipes and secure with a nut attaching the pipe bracket to the alternator

bracket stud. Tighten the nut to the correct torque specification.

Transmission oil cooler pi pe to alternator

bracket nut torque specification ...........................20 N.m

11 Remove all plugged cooler pipe/hose openings, wipe clean and recon ne c t each of the cooler hose quick connect

fittings to the cooler pipes. Tug on each after installation, to check that engagement is correct.

Refer to 3.4 Transmission Fluid Cooler Pipes/Hoses, Reinstall, in this Section.

12 Install NEW O-rings to the fluid cooler pipes at the transmis sion end, then reinstall them to the transmission.

Refer to 3.4 Transmission Fluid Cooler Pi pes/Hoses, Reinstall, in this Section.

13 Align the torque converter to flexplate orientation marks made before removal of the three attaching bolts.

14 Loosely install a NEW torque converter to flexplate attaching bolt.

15 Rotate the engine harmonic bala ncer attaching bolt in a clockwise direction only, to align the next torque converter

to flexplate attaching bolt hole, then loosely installing a NEW bolt.

16 Repeat Step 9 for the remaining torqu e to fle xplate attaching bolt, then tighten all bolts to the correct torque

specification.

Torque converter to flexplate

attaching bolt torque specification........................65 N.m

17 Reinstall the lower cover to the torque co nverter housing (‘5’ in Figure 7E4 – 109).

18 Reinstall the starter motor. Refer to Section 6D1-2 Starting System – V6.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 69

7E4 – 69

19 Reinstall the transmission wiring harness connector to the transmission control module (TCM) and check that the

sealing grommet is correctly installed to the cockpit mod ule from the engine side.

Refer to 3.21 Transmission Control Modul e, in this Section.

20 Remove the tie wire supporting the front propeller

shaft.

21 Smear some NLGI No. 2 lithium soap based EP

grease with molybdenum disulphide such as Shell

Retinax HDX2 grease, BP Energrease LMS-EP 23 or

equivalent over the transmission outp ut shaft spigot.

22 Install the propeller shaft front coupling to the output

flange, aligning the marks (A) made before removal.

NOTE

Refer to the 'Caution' stateme nt at the beginning

of this service operation to determine whether

the bolts are to be replaced or not.

23 Install fasteners to secure the coupling to the

transmission output flange. Tighten the bolts to the

correct torque specification.

Front propeller shaft couplin g nuts

or bolts and nuts torque specification.................115 N.m Figure 7E4 – 110

Front coupling bolts to ‘Spiralock’

flange threads torque specification ......................85 N.m

24 Reinstall the transmission ma nual shaft lever and its

attaching nut.

25 While holding the transmiss ion manual shaft lever with

an adjustable wrench, tighten the transmissi on manual

shaft lever retaining nut to the correct torque

specification.

Transmission manual shaft le ver

attaching nut torque specification.........................12 N.m

26 Check and adjust the shift control linkage, as required.

Refer to 3.2 Selector Linkage, Adjust, in this Section.

Figure 7E4 – 111

27 Reinstall the exhaust pipes and catalytic converters. Refer to Section 8B Exhaust System.

28 Reinstall the engine thermostat housing and replenish the engine c oolant.

Refer to Section 6B1 Engine Coolin g – V6 Engine.

29 Connect the battery negative cable. Refer to Section 0 0 Ca utions and Notes, 5 Battery Disconnection Procedures.

30 Re-program the transmission control mo dule (TCM).

Refer to 3.21 Transmission Control Modul e (TCM), Programming Procedure, in this Section.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 70

7E4 – 70

Transmission Final Test and Inspection

Complete the following procedure after the transmission has been installed in the vehicle:

1 Flush the transmission oil cooler, pipes and hoses.

Refer to 2.2 Transmission Cooler R everse F lush and Flow Rate Check, in this Section.

2 Remove the engine control relay. Refer to Section 6C1-1 Engine Management – V6 – General Information for the

location of this relay.

3 Crank the engi ne several times and listen for any unusual noises or evidence that any parts are binding.

4 Reinstall the e ngine control relay, start the engine and listen for an y abnormal conditions.

5 With the engin e runn ing at idle speed, raise the vehicle and support in a s afe mann er.

Refer to Section 0A General Information for the location of recomme nded lifting and support points.

6 With the engin e contin uing to run at idle speed, inspect under the vehicle for any fluid leaks. Correct any condition

not considered to be to specification.

7 Check the transmission fluid level, topping up as required. Refer to 2.1 Transmission Fluid Check, in this Section.

8 Lower vehicle to the grou nd.

9 Perform a final inspection of all fluid levels.

10 Road test the vehicle to ensure correct operation.

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 71

7E4 – 71

3.23 Torque Converter and/or Seal

LT Section No. – 04-200

ATTENTION

The following fasteners MUST be replaced when performin g these operations:

 Torque converter to flexplate attaching bolts.

 Front propeller shaft fasteners, as noted in th e text.

Replace

1 Remove the transmission from the vehicle. Refer to 3.22 5L40E – Automatic Transmission, in this Section.

Take care when removing the torque

converter as it is a heavy assembly

(approximately 12 kilograms) and personal

injury may result if lifted incorrectly.

2 Remove the torque converter assembly (1) by sliding it

clear of the input turbine shaft. Drain fluid stored into

the converter, into a suitable container.

Figure 7E4 – 112

3 Using a fine bladed screwdriver, lever out and remove

the input turbine shaft seal (430). Discard the removed

O-ring.

Figure 7E4 – 113

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 72

7E4 – 72

4 Remove the two screws (1), using Torx bit T20 and

suitable equipment.

5 Remove the torque converter seal (2) using Tool

J 45000 (as shown), E308 or commercial equivalent.

Figure 7E4 – 114

6 Assemble driver, T ool J 8092 to seal installer, Tool

J 44766.

NOTE

Install the seal onto the installation tool before

installing into the case to prevent damage to the

seal lips.

7 Lubricate the l ips of a new oil seal (229) with clean

automatic transmission fluid (Dexron III ®).

8 Install the seal (229) onto installer, Tool J 44766.

9 While alig ning the retaining screw holes, install the

new seal (229) into the housing (3).

10 Install new seal screws (228) and tighten to the correct

torque specification.

Torque converter seal to housing

screw torque specification...................................... 4 N.m F igure 7E4 – 115

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 73

7E4 – 73

11 Lubricate a NEW input shaft O-ring seal (43 0) with

transmission fluid and install to the groove provided.

Figure 7E4 – 116

12 Lubricate the seal running area of the torque converter

hub with clean, Dexron III™ transmission fluid.

13 Reinstall the torque converter assembly (1) by sliding

it onto the input turbine shaft.

14 Rotate the torque converter back and forth to ensure

spline engagement and full installation.

15 Lubricate the torque converter spigot with a smear of

an NLGI No. 2 lithium soap based EP grease with

molybdenum disulphide, such as Shell Retinax HDX2

grease or BP Energrease LMS-EP 23 (or eq uivalent).

16 Reinstall the transmission, refer to

3.22 5L40-E Automatic Transmission, Reinstall, in this

Section.

Figure 7E4 – 117

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 74

7E4 – 74

4 Specifications

NOTE

Only those specifications related to the service

operations contained in this Section, are listed

here.

General

Type..........................................................................................................Hydra-matic 5L40-E

Transmission Model Application HFV6 3.6 litre Petrol (RWD – P/O LY7).....................5HAG

Special Features....Electronically controlled shift pattern, feel and torque converter operation

Selector Location................................................................................. Floor mounted console

Gear Ratios

Park (P) ................................................................................................................................. –

Reverse ® .......................................................................................................................3.03:1

Neutral (N)............................................................................................................................. –

5th Gear (D).....................................................................................................................0.75:1

4th Gear (4).....................................................................................................................1.00:1

3rd Gear (3).....................................................................................................................1.60:1

2nd Gear (2).....................................................................................................................2.21:1

1st Gear (L) .....................................................................................................................3.42:1

Shift Speeds

Refer to Automatic Transmission – Section 7E3 – 5L40-E – Hydraulic and Mechanical Diagnosis.

Fluid Pressure

Refer to Automatic Transmission – Section 7E3 – 5L40-E – Hydraulic and Mechanical Diagnosis.

Torque Converter

Number of Elements..................................................................3 plus torque converter clutch

Maximum Torque Ratio at Stall 3.6 litre petrol engine (P/O LY7)...................1.90:1 (k=149)

Nominal Diameter 3.6 litre petrol engine (P/O LY7).............................258 mm

Lubricant

Type Recommended....................................................................................Dexron® III

Total (Dry) .......................................................................................................8.5 litres

Service Refill (Approximate for an ‘On-Car’ situation)................................................. 4.6 litres

Fluid Cooling..................................................Engine coolant to fluid in right side radiator tank

Techline

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 75

7E4 – 75

Electrical Component Resistance Specifications

Component Circuit

Number Wire

Colour

Inline

Connector

Resistance at

20°C Resistance at

70°C Resistance to Ground

(Transmission Case)

1525 WH 17

1 – 2 Shift

Solenoid Valve 1222 BK 14 15.0 – 17.0 Ω 17.9 – 20.3 Ω Greater than 50 kΩ

1525 WH 17

2 – 3 Shift

Solenoid Valve 1223 BU 9 15.0 – 17.0 Ω 17.9 – 2 0.3 Ω Greater than 50 kΩ

1525 WH 17

4 – 5 Shift

Solenoid Valve 898 GY 5 15.0 – 17.0 Ω 17.9 – 20.3 Ω Greater than 50 kΩ

1228 GN 13

Pressure Control

Solenoid Valve 1229 WH 8 3.5 – 4.6 Ω 4.2 – 5.5 Ω Greater than 50 kΩ

1525 WH 17

TCC PWM

Solenoid Valve 422 YE 20 10.0 – 11.5 Ω 11.8 – 13.6 Ω Greater than 50 kΩ

1230 YE 18

Input Speed

Sensor 1231 WH 15 325 – 485 Ω 385 – 575 Ω Greater than 50 kΩ

400 OR 1

Output Speed

Sensor 401 WH 3 325 – 485 Ω 385 – 575 Ω Greater than 50 kΩ

1227 RD 10

TFT Sensor 2762 WH 6 Refer to following chart for TFT Sensor Resistance

Specifications

All wire colours are internal to the transmission

Transmission Fluid Temperature (TFT) Sensor Resistance Specifications

Temperature (°C) Minimum

Resistance (Ω) Nominal

Resistance (Ω) Maximum

Resistance (Ω)

-40 89 500 100 000 110 500

-30 46 419 51 400 56 381

-20 25 120 27 610 30 100

-10 14 160 15 450 16 740

0 8 278 8 972 9 666

10 5 005 5 391 5 777

20 3 120 3 342 3 564

30 2 000 2 132 2 264

40 1 317 1 397 1 477

50 888 938 988

60 613 645 677

70 432 453 474

80 310 324 338

90 228 237 246

100 170 176 182

110 128 132 136

120 98 101 104

130 77 79 81

140 60 62 64

150 48 49 50

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 76

7E4 – 76

5 Torque Wrench Specifications

ATTENTION

Fastener torque wrench specifications may be accompanied with the following identification marks:

 Fasteners must be replaced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one or more of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

Close out cover to torque converter housing screw................................14 N.m

Cooler pipe tube nut to cooler fitting.......................................................25 N.m

Control valve body assembly to transmission case bolt .........................11 N.m

Drain plug...............................................................................................20 N.m

Extension housing retaining bolt.............................................................22 N.m

Filler plug................................................................................................20 N.m

Fluid cooler pipe bracket nut to alternator bracket..................................20 N.m

Fluid cooler pipe flange bolt to transmission case torque.......................20 N.m

Fluid pan bolt..........................................................................................11 N.m

 Front propeller shaft coupling attaching bolts or bolts and nuts............115 N.m

Front propeller shaft coupling bolts to ‘Spiralock’ flange threads............85 N.m

Input speed sensor retaining screw........................................................11 N.m

Manual shift shaft lever retaining nut......................................................12 N.m

Manual shaft detent spring bolt ..............................................................11 N.m

Oil cooler pipe to radiator fitting..............................................................25 N.m

 Output flange retaining nut.....................................................................60 N.m

Output speed sensor retaining screw.....................................................11 N.m

Pressure test plug ..................................................................................11 N.m

Rear crossmember to underbody side rail bolt.......................................58 N.m

Shift selector lever locking bolt...............................................................30 N.m

Shift selector base retaining nut.............................................................15 N.m

Torque converter oil seal to front housing retaining scre w .......................4 N.m

 Torque converter to flexplate attaching bolt............................................65 N.m

Transmission mount to crossmember nut...............................................25 N.m

Transmission mount plate to extension housing bolt..............................55 N.m

Transmission mount to mount plate nut .................................................55 N.m

Transmission to engine bolt....................................................................60 N.m

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 77

7E4 – 77

6 Special Tools

NOTE

Only those special tools quoted in this Section,

are listed here.

Tool Number Illustration Description Classification

AU 525

Quick Connect Release Tool

Used to release the quick connect

fittings on the automatic transmission

fluid cooler lines at the radiator end.

Previously released.

Unique

AU 583 Selector Shaft Seal Remo ver/

Installer

Used to remove and install the manual

shaft oil seal with the transmission

installed in the vehicle.

Previously released.

Unique

DT-47735

Holding Tool

Used to hold the final drive pin ion

flange when loosening/ti ghtening the

pinion nut.

New release

Unique

J 6125-1B Slide Hammer & Adaptor

Used in conjunction with seal

remover, J 23129 to remove both fluid

filter seals from the fluid pump

Previously released.

Unique

J 8092

Driver Handle

Used in conjunction with J 44766 to

install new torque converter seal

Previously released

Unique

J 23129 Universal Seal Remover

Used in conjunction with slide hammer

J 6125-1B to remove fluid seals.

New release.

Unique

Automatic Transmission – 5L40-E – On-Vehicle Servicing 7E4 – 78

7E4 – 78

Tool Number Illustration Description Classification

J 44246 Solenoid Testing Kit

Used to test the shift solenoid valves

for leakage.

New release

Available

J 44765

Seal Installer

Used to install the extension housi ng,

propeller shaft oil seal.

New release

Unique

J44766

Seal Installer

Used in conjunction with driver handle

J 8092 to install new torque converter

seal.

New release.

Unique

J 45000

Seal Remover

Used to remove lipped seals.

Also released as E308 and is

commercially available.

New release.

Available