1. Copyright © 2007 General Motors Corporation.
All Rights Reserved.

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

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

4. Web Site

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

6. 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.

7. 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

8. 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

9. 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

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

11. 6T40/45 Applications
Chevrolet Malibu
Saturn AURA
Pontiac G6

12. (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. 0001

13. 6T40/45 Automatic Transmission

14. 6T40/45 Design Features

15. 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

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

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

18. Tow Vehicle Considerations
Towing capacity
Towing distance
Towing equipment
Vehicle readiness

19. Dinghy Towing

20. 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.

21. Dinghy Towing – from the rear

22. Recreational Towing – Dolly Towing

23. 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.

24. 6T40 Components Gear-Type Fluid Pump Assembly
Pressure Tap & Oil Level Plug
Drain Plug
Apply Components
Planetary Gearsets

25. 6T40 Components cont. Torque Converter Fluid Level Control Valve
Control Solenoid (w/Body and TCM) Valve Assembly
Drive Link Assembly

26. Fluid Pump Assembly

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

28. Pressure Tap & Oil Level Plug

29. Drain Plug

30. Apply Components

31. Planetary Gearsets Planetary Gearsets assembled Planetary Gearsets
disassembled

32. Torque Converter Sub-assemblies

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

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

35. Control Solenoid (w/Body and TCM) Valve Assembly

36. Bottom of Solenoid Assembly

37. Solenoid Assembly 14-Way Connector

38. Drive Link Assembly

39. 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

40. 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

41. 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

42. 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

43. 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

44. 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

45. 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

46. Control Valve Body Cover

47. Cover & Gasket

48. Connector Hole Seal

49. 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.

50. Solenoid Assembly & Filter Plate Solenoid Assembly Solenoid Assembly

51. Output Speed Sensor (OSS)
OSS – possible cable
crushed

52. Input Speed Sensor (ISS)
Possible cable crushed

53. 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.

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

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

57. Control Solenoid Valve & TCM Solenoid Performance Test

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

59. Control Solenoid Valve & TCM Solenoid Performance Test cont.

60. 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.

61. 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

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

63. 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

64. 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.

65. Service Fast Learn Adapts Steps
PARK

66. 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.

67. Service Fast Learn Adapts Steps cont.
PARK
DRIVE

68. 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.

69. Service Fast Learn Adapts Steps cont.
PARK
DRIVE
REVERSE

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

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

72. Manual Shift Detent w/Shaft Position Switch Lever Assembly

73. 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

74. 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

75. 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
4-5-6
Low & Reverse

76. 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

77. 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

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

80. 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 ( °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

81. 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

82. 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

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

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

85. 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.

86. 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.

87. 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.

88. Transmission Fluid

89. 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)

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

91. Transmission Fluid Temperature

92. 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.

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

94. 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

95. To Obtain Posttest Results
After 5 Business Days go to:
Select “Training Records” from menu
Select “View Your Training Records”

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

97. Copyright © 2007 General Motors Corporation.
All Rights Reserved.