Copyright © 2007 General Motors Corporation. All Rights Reserved.

Transmissions New & Updates: 6T40/45 17440.12D Welcome to Transmissions New & Updates: 6T40/45 17440.12D

The material contained in this course component was accurate and current at the time of course development

Web Site www.gmtraining.com

Question 1 In which of the following regions is your dealership located? Atlanta Chicago Dallas Los Angeles New York

Course Goal Upon successful completion of this course, you will be able to apply concepts and procedures to diagnose and repair concerns related to the Hydra-matic 6T40/6T45 automatic transmission.

Session Objectives Describe 6T40/45 automatic transmission components and operation Describe 6T40/45 transmission specifications Explain towing procedure for the 6T40/45 equipped vehicles Use Range Reference Chart to diagnose concerns

Session Objectives cont. Describe the Control Solenoid Valve & Transmission Control Module Assembly Cleaning procedure Describe the Service Fast Learn Adapts procedure Describe the fluid checking procedure

Module 1 Objectives Describe the operation of the 6T40/45 automatic transmission Describe specifications of the 6T40/45 transmission Explain proper towing procedure with the 6T40/45 equipped vehicles Describe components of the 6T40/45 automatic transmission

Module 1 Topics Applications Introduction to 6T40 Towing 6T40-equipped vehicle Overview of Components

6T40/45 Applications Chevrolet Malibu Saturn AURA Pontiac G6

(Fill-in-the-blanks) 6T40 Trans. ID Info. (Fill-in-the-blanks) Code for A/T Model Year Model for Trans. Trans. Family Plant Source Code Calendar Year Julian Date Shift/Line (A/B) Num. seq. @ 0001

6T40/45 Automatic Transmission

6T40/45 Design Features

Fill-in-the-Blanks Exercise 4.58 2.96 1.91 1.45 1.00 0.75 2.94 6T40 = 3.17 6T45 = 3.87

Question Which gear is the 1:1 gear ratio in the 6T40? Call in Now

Towing Types Towing w/Recreational Vehicle Towing a Trailer Dinghy Dolly

Tow Vehicle Considerations Towing capacity Towing distance Towing equipment Vehicle readiness

Dinghy Towing

NOTICE: If you exceed 65 mph (105 km/h) while towing your vehicle, it could be damaged. NEVER exceed 65 mph (105 km/h) while towing your vehicle.

Dinghy Towing – from the rear

Recreational Towing – Dolly Towing

CAUTION When towing a trailer, the cooling system may temporarily overheat during severe operating conditions. Refer to Service Information for correct information and towing considerations.

6T40 Components Gear-Type Fluid Pump Assembly Pressure Tap & Oil Level Plug Drain Plug Apply Components Planetary Gearsets

6T40 Components cont. Torque Converter Fluid Level Control Valve Control Solenoid (w/Body and TCM) Valve Assembly Drive Link Assembly

Fluid Pump Assembly

Pump Related Diagnostic Tips Transmission Overheating Loss of Drive High or Low Line Pressure Slipping Clutch or Harsh Apply

Pressure Tap & Oil Level Plug

Drain Plug

Apply Components

Planetary Gearsets Planetary Gearsets assembled Planetary Gearsets disassembled

Torque Converter Sub-assemblies

Tech Tip: Torque converter failure could cause loss of drive gear and/or loss of power.

Fluid Level Control Valve (inside transmission) Fluid level control valve (outside transmission)

Control Solenoid (w/Body and TCM) Valve Assembly

Bottom of Solenoid Assembly

Solenoid Assembly 14-Way Connector

Drive Link Assembly

Module 1 Summary Described operation of the 6T40 Described specifications of the 6T40 Explained the proper procedure for towing with the 6T40 Described components of the 6T40

Posttest Question 1 10 9 11 13 14 8 12 7 2 1 3 4 6 5 15 17 26 25 27 28 30 29 16 24 19 18 23 20 21 22 The purpose of the Fluid Level Control Valve is to control fluid level in the ___________. Torque Converter Control Solenoid Control Valve Case Control Valve Cover Assembly

Posttest Question 2 10 9 11 13 14 8 12 7 2 1 3 4 6 5 15 17 26 25 27 28 30 29 16 24 19 18 23 20 21 22 How many shift solenoids are there in the 6T40? 1 2 3 4

Posttest Question 3 10 9 11 13 14 8 12 7 2 1 3 4 6 5 15 17 26 25 27 28 30 29 16 24 19 18 23 20 21 22 When dinghy towing, the vehicle should be run at the beginning of each day and at each RV fuel stop for about ________ minutes. 5 10 15 30

Posttest Question 4 10 9 11 13 14 8 12 7 2 1 3 4 6 5 15 17 26 25 27 28 30 29 16 24 19 18 23 20 21 22 How many Planetary Gearsets are used in the 6T40? 1 2 3 4

Posttest Question 5 10 9 11 13 14 8 12 7 2 1 3 4 6 5 15 17 26 25 27 28 30 29 16 24 19 18 23 20 21 22 Which engine is used for the first application of the 6T40? 2.2L 2.4L 3.4L 3.6L

Module 2 Objectives Explain Shift Speed Variables for the 6T40 Explain use of the Range Reference Chart Describe the Control Solenoid Valve & TCM Assembly Cleaning procedure Describe Service Fast Learn Adapts procedure

Control Valve Body Cover

Cover & Gasket

Connector Hole Seal

Tech Tip: Support the control solenoid valve assembly around the connector when removing the seal. Excessive pulling force can damage the internal electrical connections. Discard the seal. It is not reusable.

Solenoid Assembly & Filter Plate Solenoid Assembly Solenoid Assembly

Output Speed Sensor (OSS) OSS – possible cable crushed

Input Speed Sensor (ISS) Possible cable crushed

Control Solenoid Valve & TCM Assembly Cleaning Operate transmission to 70°–90°C (158°–194°F) Select Service Cleaning Procedure & initiate cleaning procedure When procedure is completed, shut ignition OFF for 30 secs.

Control Solenoid Valve & TCM Assembly Cleaning cont. Restart engine & operate vehicle based on criteria Observe if DTC(s) have run & passed

Control Solenoid Valve & TCM Solenoid Performance Test Bolting DT-48616 to Solenoid DT-48616 Torque Sequence

Control Solenoid Valve & TCM Solenoid Performance Test

CAUTION Do NOT energize the solenoids for more than two minutes or the solenoids could be damaged.

Control Solenoid Valve & TCM Solenoid Performance Test cont.

CAUTION Only perform the Performance Test on the suspect solenoid. During the performance test with the Key ON/Engine OFF, the TCM will normally cycle some of the solenoids ON and OFF to keep the ports and solenoids clear. This may cause air to exit the ports where the gauge is NOT connected.

Service Fast Learn Adapts Procedure Transmission internal service/ overhaul Valve body repair or replacement Solenoid Assembly replacement TCM software/calibration update Service in response to shift quality concern

Service Fast Learn Adapts Procedure Conditions Block drive wheels Apply parking brake Apply service brake

Service Fast Learn Adapts Procedure Conditions cont. 0% throttle / No RPM control 70º–100ºC (158º–212ºF) TFT Gear selector cycled 3X from P to R

Tech Tip: If at any time during the procedure, required conditions are not met, Service Fast Learn Adapts may abort and the process may need to be started again from the beginning. If power is lost or if the scan tool is disconnected, the procedure must be started over.

Service Fast Learn Adapts Steps PARK

CAUTION Block the wheels before selecting DRIVE. While in DRIVE, if the Scan Tool loses communication or becomes disconnected, the vehicle could move FORWARD. Failure to block the wheels could result in personal injury or property damage.

Service Fast Learn Adapts Steps cont. PARK DRIVE

CAUTION Block the wheels before selecting REVERSE. While in REVERSE, if the Scan Tool loses communication or becomes disconnected, the vehicle could move. Failure to block the wheels could result in personal injury or property damage.

Service Fast Learn Adapts Steps cont. PARK DRIVE REVERSE

Troubleshooting Tips 70–100ºC (158–212ºF) TFT Proper function of brakes & brake switch Verify no active DTCs Closed throttle & engine RPM > 1500 RPM

Troubleshooting Tips cont. P / N switch adjusted & functioning Line pressure provides 1000 kPa (145 psi) Vehicle not moving or vibrating

Manual Shift Detent w/Shaft Position Switch Lever Assembly

Module 2 Summary Explained Shift Speed Variables for the 6T40 Explained Range Reference Chart Described Control Solenoid Valve & Transmission Control Module Assembly Cleaning Procedure Described Service Fast Learn Adapts Procedure

Posttest Question 6 10 9 11 13 14 8 12 7 2 1 3 4 6 5 15 17 26 25 27 28 30 29 16 24 19 18 23 20 21 22 How many inputs are there from the IMS to the TCM? 1 2 4 5

Posttest Question 7 10 9 11 13 14 8 12 7 2 1 3 4 6 5 15 17 26 25 27 28 30 29 16 24 19 18 23 20 21 22 The Input Speed Sensor reluctor wheel is a part of the ______ clutch housing. 3-5-R 1-2-3-4 4-5-6 Low & Reverse

Posttest Question 8 10 9 11 13 14 8 12 7 2 1 3 4 6 5 15 17 26 25 27 28 30 29 16 24 19 18 23 20 21 22 To successfully complete the Service Fast Learn Adapts procedure, the throttle position must be ___ percent. 10 15 25

Posttest Question 9 10 9 11 13 14 8 12 7 2 1 3 4 6 5 15 17 26 25 27 28 30 29 16 24 19 18 23 20 21 22 Service Fast Learn Adapts is a procedure for 6-speed automatic transmissions in which a series of tests are run to allow the TCM to _______________. clean & synchronize the solenoids validate the shift solenoids in the TCM learn individual clutch characteristics reset & communicate with the ECM

Module 3 Objectives Apply fluid checking procedure for the 6T40 Describe temperature requirements

Transmission Fluid Check Check fluid level & condition of fluid NO fill tube on some vehicles – set fluid level w/ oil level plug Check fluid at TFT – 85-95°C (185-203°F) If TFT not w/in range – operate vehicle or allow fluid to cool TFT fluid level outside correct range results in under-fill / over-fill

Transmission Fluid Check cont. TFT > 95°C = under-filled TFT < 85°C = over-filled Under-fill could cause premature component wear / damage Over-fill will cause vent discharge / fluid foaming / pump cavitation

DEXRON®-VI For the 6T40 transmission, use DEXRON® VI transmission fluid ONLY Failure to use the proper fluid may result in internal damage to the transmission

Transmission Fluid Check cont. Connect scan tool / monitor TFT Start / idle engine Depress brake / shift gears 3 times Shift to PARK / ensure 500-800 RPM Idle 3 minutes for fluid to stabilize

Raise Vehicle Vehicle MUST be level Engine MUST be running Shift lever MUST be in PARK

Tech Tip The engine MUST be running when the transmission oil level check plug is removed or excessive fluid loss will occur, resulting in an under-filled condition. An under-filled transmission will cause premature component wear or damage.

IMPORTANT Continue to monitor the TFT. If the TFT is not within the specified values of 85ºC–95ºC (185ºF–203ºF), reinstall the transmission oil level check plug and repeat the previous steps.

Tech Tip Due to expansion of the fluid, do NOT add more than half a pint at a time without re-checking the fluid level.

Transmission Fluid

Question 2 What is the proper temperature range for checking the fluid level in a 6T40/45? 70º–90ºC (158°-194°F) 80º–100ºC (176°-212°F) 85º–95ºC (185°-203°F) 95º–105ºC (203°- 221°F)

Question Was the temperature in the video adequate to check the fluid level? Call in Now

Transmission Fluid Temperature

Tech Tip It is not necessary to get the fluid level all the way up to the maximum mark. Anywhere within the crosshatch band is acceptable.

Module 3 Summary Applied fluid checking procedure for the 6T40 Described temperature requirements

Posttest Question 10 10 9 11 13 14 8 12 7 2 1 3 4 6 5 15 17 26 25 27 28 30 29 16 24 19 18 23 20 21 22 Which gear should the vehicle be driven in to bring the temperature within proper fluid checking range? 1st 2nd 4th Reverse

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Transmissions New & Updates: 6T40/45 17440.12D Thank you for attending Transmissions New & Updates: 6T40/45 17440.12D

Copyright © 2007 General Motors Corporation. All Rights Reserved.