TECHNICAL SERVICE INFORMATION THM 4T40-E INTRODUCTION We wish to thank General Motors Corporation for the information and illustrations that have made this booklet possible. This booklet contains general description and the overhaul procedures necessary to repair, overhaul, or service the new THM 4T40-E electronic overdrive automatic transaxle. This unit will first be found in 1995 Chevrolet Cavalier and Pontiac Sunfire vehicles. The THM 4T40-E is a fully automatic front wheel drive transaxle. It provides park, reverse, neutral, and 4 forward speeds including overdrive. The shift pattem is controlled electronically with 2 shift solenoids that recieve a ground signal from the PCM (Powertrain Control Module). The PCM will vary shift points, as it is constantly interpreting numerous electronic signals from various operational sensors located on the vehicle. The PCM also controls apply and release of the Torque Converter Clutch. Line pressure and shift feel are also controlled electronically with an EPC (Electronic Pressure Control) solenoid located on the valve body and is dependent on TPS and VSS signals. "Portions of material contained herein, have been reprinted with permission of General Motors Corp, Service Technology Group” ‘The information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy. ROBERT D. CHERRNAY TECHNICAL DIRECTOR DALE ENGLAND, WAYNE COLONNA FIELD SERVICE CONSULTANT TECHNICAL SUPERVISOR ED KRUSE PETE LUBAN TECHNICAL CONSULTANT TECHNICAL CONSULTANT JIM DIAL GREGORY LIPNICK TECHNICAL CONSULTANT TECHNICAL CONSULTANT JERRY GOTT DAVID CHALKER TECHNICAL CONSULTANT TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FL 33156 ; 5 ATSG (305) 670-4161 Copyright © ATSG 1THM 4T40-E INDEX RANGE REFERENCE CHART -- 4 FLUID CHECKING PROCEDURE 6 LINE PRESSURE TEST -- 10 TROUBLE CODE RETRIEVAL AND PCM LOCATION -- 12 TROUBLE CODE CHART -~ 13 ELECTRONIC COMPONENTS AND DESCRIPTION 16 INTERNAL WIRING HARNESS SCHEMATIC -~ 21 ELECTRONIC COMPONENT RESISTANCE CHART 23 DIAGNOSTIC CHARTS - 24 TCC SHUDDER DIAGNOSIS - 36 OIL PASSAGE IDENTIFICATION 37 CHECKBALL LOCATIONS IN CHANNEL PLATE - 46 TRANSAXLE DISASSEMBLY --- 48 COMPONENT REPAIR AND TRANSAXLE ASSEMBLY 61 FORWARD CLUTCH HOUSING ASSEMBLY -- 1 DIRECT/COAST CLUTCH HOUSING ASSEMBLY 7 SELECTIVE THRUST WASHER MEASUREMENT 84 REVERSE INPUT CLUTCH HOUSING AND 2ND ROLLER CLUTCH -- 85 INPUT SPEED SENSOR ASSEMBLY a VALVE BODY ASSEMBLY -~ 96 PRESSURE SWITCH ASSEMBLY TEST PROCEDURE (OFF UNIT) 98 BEARING AND WASHER LOCATION CHART 108 TORQUE SPECIFICATIONS ng ‘SPECIAL TOOLS -- “Portions of material contained herein, have been reprinted with permission of General Motors Corp, Service Technology Group" AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 670-4161 Copyright © ATSG 1995 eareceeeet eee ee cy C4ATSGTechnical Service Information HYDRA-MATIC 4T40-E TRANSAXLE REV. INPUT CLUTCH FORWARD ecuren oIRECT = INPUT CLOTS SPRAS ‘COAST ciuTcH 10 ROLLER etuTch FORWARD 2ND ROLLER Pi ‘CLUTCH toy SUPPORT INTERMEDIATE/ATH REACTION INPUT REVERSE SAND CARRIER ASM. CARRIER ASM. BAND 2ND CLUTCH AUTOMATIC TRANSMISSION SERVICE GROUP 2