Auto Trans Service

2003 Pontiac Aztek
2003 AUTOMATIC TRANSMISSIONS Servicing - Aztek & Rendezvous
2003 AUTOMATIC TRANSMISSIONS
Servicing - Aztek & Rendezvous
APPLICATION
TRANSAXLE APPLICATION
Application Transaxle Model (RPO Code)
AWD 4T65-E (M76)
FWD 4T65-E (M15)
IDENTIFICATION
TRANSAXLE
Transaxle has a metal identification plate or Service Replacement Transaxle Assembly (SRTA) plate attached to
rear face of transaxle. See Fig. 1 .
Toshiba
Sunday, June 21, 2009 1:21:49
1:21:44 PM Page 1 2005 Mitchell Repair Information Company, LLC.
2003 Pontiac Aztek
Fig. 1: Locating Transaxle ID Plate & SRTA Plate Information

Courtesy of GENERAL MOTORS CORP.
OIL PAN GASKET
Toshiba
Sunday, June 21, 2009 1:21:44 PM Page 2 2005 Mitchell Repair Information Company, LLC.
2003 Pontiac Aztek
Fig. 2: Identifying Oil Pan Gasket (Hydra-Matic 4T65-E)

LUBRICATION
SERVICE INTERVALS
Change the ATF and filter every 50,000 miles if the vehicle is mainly driven under one or more of these
conditions:
In heavy traffic where the outside temperature regularly reaches 90F (32C) or higher.
In hilly or mountainous terrain.
When doing frequent towing.
Uses such as found in taxi, police or delivery service.
Toshiba
2003 Pontiac Aztek
If the vehicle is not used under any of these conditions, change the fluid and filter every 100,000 miles.
CHECKING FLUID LEVEL & CONDITION
1. Start the engine and allow the engine to idle until the transaxle has reached 180-200F (82-93C).
Depress the brake pedal and move the shift control lever through the gear ranges, pausing a few seconds
in each gear. Is the fluid Red or Light Brown? If so, go to step 4 . If not, go to next step.
2. Does the fluid have a burnt odor or a Dark Brown color? If so, go to step 11 . If not, go to next step.
3. Does the fluid have a cloudy or milky appearance? If so, go to step 10 . If not, go to next step.
4. Check the fluid level. The vehicle must be level, with the engine running and the shift control lever in the
Park range. Check both sides of the fluid level indicator, and read the lower level. The proper fluid level
should be in the middle of the cross-hatch. Is the fluid level too high? If so, go to step 9 . If not, go to next
step.
5. Is the fluid level low? If not, system is okay. If so, go to next step.
6. Add appropriate fluid in increments of 17 oz. (0.5L) until the fluid is in the middle of the cross-hatch.
Check both sides of the fluid level indicator, and read the lower level. Did you add more than 51 oz.
(1.5L) to the transaxle? If not, go to step 9 . If so, go to next step.
7. Check for external leaks. Did you find any leaks? If not, go to step 15 . If so, go to next step.
8. Correct the leak condition. Did you correct the leak condition? If so, go to step 15 .
9. Remove any excess fluid to the proper level, the middle of the cross-hatch. Is the fluid level satisfactory?
If so, system is okay.
10. The transaxle is contaminated with engine coolant. Replace the cooler. Is the replacement complete? If
so, go to step 12 .
NOTE: Transmission fluid may turn dark with normal use. This does not always
indicate oxidation or contamination.
11. Drain the fluid to determine if the fluid is contaminated. A very small amount of material in the bottom
pan is a normal condition, but large pieces of metal or other material in the bottom pan require a transaxle
overhaul. Was the fluid contaminated? If so, go to step 13 . If not, go to next step.
12. Overhaul the transaxle. See appropriate OVERHAUL article. Is the overhaul complete? If so, go to next
step.
13. Flush the cooler. See OIL COOLER FLUSHING . Has the cooler been flushed? If so, go to next step.
14. Change the fluid and the filter. See DRAINING & REFILLING . Is the procedure complete? If so, go to
next step.
15. Add new fluid to the proper level, in the middle of the cross-hatch. Is the procedure complete? If so,
system is okay.
RECOMMENDED FLUIDS
Manufacturer recommends DEXRON-III(R) ATF. Fill transaxle with appropriate quantity. See FLUID
CAPACITIES .
Toshiba
2003 Pontiac Aztek
FLUID CAPACITIES
TRANSAXLE FLUID CAPACITIES (1)

Application Qts. (L)
Bottom Pan Removal
AWD 7.8 (7.4)
FWD 7.4 (7.0)
Complete Overhaul
AWD 10.4 (9.8)
FWD 10.0 (9.4)
Dry Fill
AWD 13.8 (13)
FWD 13.4 (12.7)
(1) Fluid capacities listed are approximate. Always fill to specified area on dipstick. See CHECKING
FLUID LEVEL & CONDITION .
DRAINING & REFILLING
CAUTION: Do not use any type of grease to retain parts during the assembly of this
unit. Using greases other than the recommended assembly lube changes
the transaxle fluid characteristics. Using greases other than the
recommended assembly lube causes undesirable shift conditions and/or
filter clogging. Use Transjel(tm) Lubricant (J-36850) or equivalent during
the assembly of this unit.
1. Raise and support the vehicle. Place a drain pan under the transaxle bottom oil pan. Remove the oil pan
bolts (23) from the front. See Fig. 3 . Remove the oil pan bolts (23) from the sides. Loosen the rear oil
pan bolts (23) approximately 4 turns.
2. Use a rubber mallet to lightly tap the oil pan or use a screwdriver to pry the oil pan loose. Allow the fluid
to drain. Remove the remaining oil pan bolts (23).
NOTE: Ensure care is taken NOT to damage the mating surfaces of the oil pan
and of the case or oil leaks may occur.
3. Remove the oil pan (24). Remove the oil pan gasket (25). Remove the filter (100). Remove the lip ring
seal (101) pressed into the case only if replacement is necessary. Inspect the oil pan and the filter screen
for the following foreign material:
Inspect for metal particles.
Inspect for clutch facing material.
Inspect for rubber particles.
Inspect for engine coolant.
4. Determine the source of the contamination if foreign material is evident. Correct the source of the
Toshiba
2003 Pontiac Aztek
contamination. Use solvent to clean the screen and blow-dry if reusing. Install a new seal (101). See Fig.
4 . Install the filter (100). See Fig. 3 .
5. Inspect the oil pan flange (1) for distortion. See Fig. 5 . Replace the oil pan (1) if bent or distorted. Do not
attempt to straighten. Inspect the washers on the bolts when service requires the removal of the bottom oil
pan. Install a new bolt and washer assembly if the washer is inverted. See Fig. 6 .
6. Use solvent to clean the case. Air dry the case. Use solvent to clean the oil pan gasket surfaces. Air dry
the oil pan gasket surfaces. Ensure all traces of the old gasket material are removed.
NOTE: Ensure the oil pan and the case flanges are dry and are free of any oil film
or leakage may result.
7. Install the oil pan gasket (25). See Fig. 3 . Install the oil pan (24). Install the oil pan bolts (23). See Fig.
6 . Tighten the oil pan bolts (23) to specification. See TORQUE SPECIFICATIONS .
8. Lower the vehicle. Fill transaxle with appropriate fluid to proper level. See RECOMMENDED FLUIDS
and FLUID CAPACITIES . Place the gear selector in the Park position. Start the engine.
CAUTION: DO NOT overfill the transaxle. Overfilling of the transaxle causes

foaming, loss of fluid, shift complaints, and possible damage to the
transaxle.
9. Run the engine at a slow idle. Do not race the engine. Adjust the fluid level. See CHECKING FLUID
LEVEL & CONDITION . Inspect for proper completion of the repairs. Inspect for fluid leaks.
Toshiba
2003 Pontiac Aztek
Fig. 3: Removing & Installing Oil Pan & Filter

Toshiba
2003 Pontiac Aztek
Fig. 4: Installing Oil Filter Seal

Toshiba
2003 Pontiac Aztek
Fig. 5: Inspecting Oil Pan Flange

Toshiba
2003 Pontiac Aztek
Fig. 6: Identifying Conical Washers

OIL COOLER FLUSHING
CAUTION: Flushing Solution (J-35944-22) is environmentally safe, yet powerful

enough to cut through transmission fluid to dislodge any contaminants
from the cooler. The safety precautions on the label regarding potential
skin and eye irritations associated with prolonged exposure are typical
precautions that apply to many similar cleaning solutions. It should be
noted that according to General Motors, use of other non-approved fluids
for cooler flushing can have an adverse reaction to the seals inside the
transaxle.
CAUTION: DO NOT use solutions that contain alcohol or glycol. Use of solutions that
contain alcohol or glycol may damage flushing equipment, oil cooler
components and/or transaxle components.
Toshiba
2003 Pontiac Aztek
NOTE: GM studies indicate that plugged or restricted transaxle oil coolers and pipes
cause insufficient transaxle lubrication and elevated operating temperatures
which can lead to premature transaxle wear-out. Many cases could have been
prevented by following published procedures for transaxle oil cooler flushing
and flow checking. This procedure includes flushing and flow checking the
auxiliary transaxle oil cooler, if equipped. GM requires that transaxle oil cooler
flushing and flow checking be performed whenever a transaxle is removed from
the vehicle for service within warranty, including: Goodwin, SWAT, major
overhaul, torque converter replacement and oil pump replacement.
Preparation
1. After the repair or replacement transaxle is installed in the vehicle, do not reconnect the oil cooler pipes.
2. Remove the fill cap (9) on the Transmission Oil Cooler and Line Flusher (J-35944-A) and fill the flusher
tank (4) with 20 oz. (0.6L) of flushing solution using the measuring cup (6). Do not overfill. Install the fill
cap (9) on the transmission oil cooler and line flusher and pressurize the flusher tank (4) to 80-100 psi,
using the shop air supply at the tank air valve (9). See Fig. 7 .
3. Connect the transmission oil cooler and line flusher discharge hose (5) to the oil cooler return pipe (top
connector). Clip the discharge hose (5) onto the oil drain container. Attach the transmission oil cooler and
line flusher to the undercarriage of the vehicle with the hook provided, and connect the flushing system
feed supply hose (3) from the transmission oil cooler and line flusher to the oil cooler feed pipe (bottom
connector).
4. With the water supply valve (1) on the transmission oil cooler and line flusher in the OFF position,
connect the water supply hose (7) from the transmission oil cooler and line flusher to the water supply at
the faucet. See Fig. 7 and Fig. 8 . Turn on the water supply at the faucet.
Toshiba
2003 Pontiac Aztek
Fig. 7: Identifying Flushing Equipment

Toshiba
2003 Pontiac Aztek
Fig. 8: Connecting Flushing Equipment

Initial Flush
1. Turn the transmission oil cooler and line flusher water supply valve (1) to the ON position and allow
water to flow through the oil cooler and pipes for 10 seconds to remove any remaining transmission fluid.
See Fig. 9 . If water does not flow through the oil cooler and pipes, the cause of the blockage must be
diagnosed and the plugged component must be repaired or replaced. Continue with the cooler flushing
and flow check procedure once the blockage is corrected.
2. Turn the transmission oil cooler and line flusher water supply valve (1) to the OFF position and clip the
discharge hose (5) onto an appropriate container with a lid, to avoid splashback. See Fig. 10 . Turn the
transmission oil cooler and line flusher water supply valve (1) to the ON position and depress the trigger
(8) to mix cooler flushing solution into the water flow. See Fig. 7 . Use the clip provided on the handle to
hold the trigger (8) down. The discharge will foam vigorously when the solution is introduced into the
Toshiba
2003 Pontiac Aztek
water stream.
3. Flush the oil cooler and pipes with water and solution for 2 minutes. During this flush, attach the shop air
supply of 120 psi to the flushing system feed air valve (2) located on the transmission oil cooler and line
flusher for 3-5 seconds at the end of every 15-20 second interval to create a surging action.
NOTE: Flushing for approximately 2 minutes in each cooler line direction will
result in a total of about 8-10 gallons of waste fluid. This mixture of water
and flushing fluid is to be captured in an appropriate container for proper
disposal.
4. Release the trigger (8) and turn the transmission oil cooler and line flusher water supply valve (1) to the
OFF position.
Toshiba
2003 Pontiac Aztek
Fig. 9: Flushing Oil Cooling System

Toshiba
2003 Pontiac Aztek
Fig. 10: Capturing Fluid Discharge

Back Flush
1. Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil cooler pipe.
This will allow the oil cooler and pipes to be back flushed. Repeat steps 2 and 3 of the INITIAL FLUSH
procedure. Release the trigger (8) of the transmission oil cooler and line flusher and allow water only to
rinse the oil cooler and pipes for one minute.
2. Turn the transmission oil cooler and line flusher water supply valve (1) to the OFF position and turn off
the water supply at the faucet. See Fig. 8 . Attach the shop air supply to the flushing system feed air valve
(2) on the transmission oil cooler and line flusher, and blow out the water from the oil cooler and pipes.
Continue until no water comes out of the discharge hose (5).
OIL COOLER FLOW TEST
Flow Check
1. Disconnect both hoses from the oil cooler pipes. Connect the oil cooler feed pipe (vertical/top connector)
to the transaxle and the return pipe (horizontal/bottom connector) to the discharge hose (5). Clip the
Toshiba
2003 Pontiac Aztek
discharge hose (5) onto the empty oil drain container. See Fig. 10 .
2. Confirm the transaxle is filled with fluid. See CHECKING FLUID LEVEL & CONDITION . Start the
engine with the transaxle in Park range and run for 30 seconds. A minimum of 2 qts. (1.9L) must be
discharged during this 30-second run time. If fluid flow is greater than 2 qts. (1.9L) in 30 seconds, go to
next step. If fluid flow is less than 2 qts. (1.9L) in 30 seconds, perform the following diagnosis:
Disconnect the oil cooler feed line at the radiator. Connect the discharge hose (5) to the cooler feed line.
Clip the discharge hose (5) to the empty oil drain container. See Fig. 10 . Start the engine with the
transaxle in Park range and run for 30 seconds. A minimum of 2 qts. (1.9L) must be discharged during
this 30-second run time. Do the following according to the flow rate:
Insufficient feed flow: inspect the transaxle.
Sufficient feed flow: inspect the oil cooler return pipe and the oil cooler (and auxiliary cooler, if
equipped).
3. Remove the discharge hose (5), reconnect the cooler feed and return pipes to the transaxle and refill
transaxle with appropriate fluid to proper level. See RECOMMENDED FLUIDS and FLUID
CAPACITIES . Inspect the transaxle oil cooler pipe connections at the radiator, the auxiliary cooler (if
equipped) and the transaxle for leaks.
Clean-up
Disconnect the water supply hose (7) from the transmission oil cooler and line flusher and bleed any remaining
air pressure from the flusher tank (4). See Fig. 7 . Remove the fill cap (9) from the transmission oil cooler and
line flusher and return any unused flushing solution to its container. Rinse the transmission oil cooler and line
flusher with water. DO NOT store the transmission oil cooler and line flusher with flushing solution in it. After
every 3rd use, clean the transmission oil cooler and line flusher as described in the instructions included with
the tool. Dispose of any waste water/solution and transmission fluid in accordance with local regulations.
ON-VEHICLE REPAIRS
NOTE: Various components may be serviced without transaxle removal. For servicing
of these components, see appropriate component under ADJUSTMENTS and/or
REMOVAL & INSTALLATION . For additional information on servicing electrical
components, see appropriate DIAGNOSIS article.
ADJUSTMENTS
WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system.

When servicing vehicle, use care to avoid accidental air bag deployment.
SIR system-related components are located in various locations
throughout interior and exterior of vehicle, depending on application. DO
NOT use electrical test equipment on or near these circuits. If necessary,
deactivate SIR system before servicing components. See AIR BAG
DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
SHIFT CABLE
Toshiba
2003 Pontiac Aztek
NOTE: Adjust the shift cable while the transaxle and while the gear selector are in the
Neutral position only. Failure to do so may cause misadjustment of shift cable.
1. Set the parking brake. Block the wheels. Use an appropriate tool to pry on the shift cable terminal at the
manual control lever pin to remove the shift cable terminal from the manual control lever pin. See Fig.
11 .
2. Fully lift the adjuster lock button. Ensure the adjuster is free to move. Rotate the manual control lever
fully counterclockwise to the Park gear, then rotate the lever clockwise 2 clicks into the Neutral gear to
place the manual control lever in the Neutral gear.
3. Perform the following steps to place the inside car gear shifter in the Neutral position:
A. Rotate the shift control lever to the L1 position, fully down.
B. Push forward on the lever while slowly pushing up. The shift control lever moves up while clicking
over the gear over travel stops.
C. Release the shift control lever once the shift control lever stops solidly. The shift control lever is in
the Neutral gear.
4. Grasp the shift cable terminal in the underhood. Pull the shift cable terminal toward the pin on the manual
control lever. The shift cable adjuster spring should compress as the terminal is moved toward the pin.
5. Carefully push down the pin until the pin snaps to attach the pin to the manual control lever. DO NOT
move the manual control lever out of position. DO NOT pull the terminal beyond the pin then push back
or the shifter may move out of the Neutral gear.
6. Press the adjuster lock button down flush with the adjuster body. See Fig. 12 . Shift to Park. Release the
parking brake while applying the service brake. Start the engine. Ensure all the indicated gear positions
match the vehicle response.
Toshiba
2003 Pontiac Aztek
Fig. 11: Adjusting Shift Cable (1 Of 2)

Fig. 12: Adjusting Shift Cable (2 Of 2)

Toshiba
2003 Pontiac Aztek
REMOVAL & INSTALLATION
WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system.

When servicing vehicle, use care to avoid accidental air bag deployment.
SIR system-related components are located in various locations
throughout interior and exterior of vehicle, depending on application. DO
NOT use electrical test equipment on or near these circuits. If necessary,
deactivate SIR system before servicing components. See AIR BAG
DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.
NOTE: Use the correct fastener in the correct location. Replacement fasteners must be
the correct part number for that application. Fasteners requiring replacement or
fasteners requiring the use of thread locking compound or sealant are identified
in the service procedure. DO NOT use paints, lubricants, or corrosion inhibitors
on fasteners or fastener joint surfaces unless specified. These coatings affect
fastener torque and joint clamping force and may damage the fastener. Use the
correct tightening sequence and specifications when installing fasteners in
order to avoid damage to parts and systems.
NOTE: Some removal and installation procedures may require the removal of engine
and/or transaxle mounts. For procedures related to these components, see
appropriate REMOVAL & INSTALLATION article.
ACCUMULATOR & 2-1 MANUAL SERVO
Removal
1. Raise and support the vehicle. Remove the oil pan. Remove the filter. See DRAINING & REFILLING
under LUBRICATION.
2. Remove the accumulator bolts. Remove the manual 2-1 band servo cover bolts. See Fig. 13 .
3. Use a large flat-blade tool in order to gently pry the lube oil pipe retainer from the case. See Fig. 14 .
Remove the lube oil pipe from the front differential carrier internal gear lube hole. See Fig. 15 .
4. Remove the accumulator. Remove the manual 2-1 band servo cover. Remove the manual 2-1 band servo.
Remove the manual 2-1 band servo cover gasket. See Fig. 16 .
5. To disassemble, inspect and service the accumulator and 2-1 manual servo, see appropriate OVERHAUL
article.
Toshiba
2003 Pontiac Aztek
Fig. 13: Identifying Accumulator & 2-1 Manual Servo Cover Bolts
Toshiba
2003 Pontiac Aztek
Fig. 14: Removing & Installing Lube Oil Pipe

Toshiba
2003 Pontiac Aztek
Fig. 15: Removing & Installing Accumulator & 2-1 Manual Band Servo
Toshiba
2003 Pontiac Aztek
Fig. 16: Removing & Installing 2-1 Manual Band Servo & Seal
Installation
1. Install the manual 2-1 band servo cover gasket into the case. Lubricate the manual 2-1 band servo cover
gasket with automatic transmission fluid. Install the manual 2-1 band servo. See Fig. 16 . Install the
manual 2-1 band servo cover. See Fig. 15 .
2. Install the manual 2-1 band servo cover bolts. See Fig. 13 . Tighten the bolts to specification. See
TORQUE SPECIFICATIONS . Install the accumulator. Install the lube oil pipe into the case at the lube
hole for the front differential carrier internal gear.
3. Use a flat-blade tool in order to lock the lube oil pipe retainer into the case. Tighten the accumulator
attaching bolts to specification. See TORQUE SPECIFICATIONS .
4. If removed, install the new filter seal. Install the filter. Install the oil pan. See DRAINING &
REFILLING under LUBRICATION. Lower the vehicle.
5. Fill transaxle with appropriate fluid to proper level. See LUBRICATION .
Toshiba
2003 Pontiac Aztek
CASE EXTENSION HOUSING
Removal
1. Raise and support the vehicle. Disconnect the right drive axle from the transaxle. See appropriate AXLE
SHAFTS article in DRIVELINE/AXLES. Remove the transaxle brace. See TRANSAXLE BRACE .
2. Remove the vehicle speed sensor. See VEHICLE SPEED SENSOR . Remove the case extension
housing bolts. See Fig. 17 .
3. Remove the case extension housing with axle seal and the "O" ring. Inspect the case extension for the
following conditions:
Damaged or porous sealing surface for the case extension seal.
Damaged or porous sealing surface for the vehicle speed sensor.
Damaged or porous sealing surface for the right drive axle oil seal.
Damaged or porous sealing surface for the case extension housing.
Damaged or worn differential carrier bushing or output shaft bearing.
Damaged bolt holes.
Inspect the drive axle seal and replace if necessary.
Toshiba
2003 Pontiac Aztek
Fig. 17: Removing & Installing Case Extension

Installation
1. Perform differential carrier end play inspection. See appropriate OVERHAUL article. If removed, install
the drive axle seal. Install the case extension housing with the axle seal and the "O" ring. See Fig. 17 .
2. Install the case extension housing bolts. Tighten the case extension housing bolts to specification. See
TORQUE SPECIFICATIONS . Install the vehicle speed sensor. See VEHICLE SPEED SENSOR .
3. Install the transaxle brace. See TRANSAXLE BRACE . Connect the right drive axle to the transaxle.
See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Lower the vehicle.
4. Fill transaxle with appropriate fluid to proper level. See LUBRICATION . Inspect for completion of the
repairs. Inspect for fluid leaks.
Toshiba
2003 Pontiac Aztek
WARNING: DO NOT overfill the transaxle. Overfilling of the transaxle causes

foaming, loss of fluid, shift complaints, and possible damage to the
transaxle.
CASE SIDE COVER
Removal
1. Disconnect the negative battery cable. Remove the throttle body air inlet duct. Install the engine support
fixture. See appropriate REMOVAL & INSTALLATION article. Remove the engine mount struts. Raise
and support the vehicle.
2. Remove the left front tire and wheel. Remove the left engine splash shield. Remove the stabilizer shaft
links from the lower control arms. See appropriate FRONT article in SUSPENSION. Remove the left tie
rod end from the steering knuckle. See appropriate FRONT article in SUSPENSION.
3. Remove the wheel speed sensor harness connector. Remove the left lower ball joint from the left steering
knuckle. See appropriate FRONT article in SUSPENSION. Disconnect the left drive axle from the
transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Reposition and secure the
drive axle.
4. Remove the intermediate shaft from the steering gear. See appropriate POWER RACK & PINION article
in STEERING. Disconnect the catalytic converter pipe from the right (rear) exhaust manifold. Support
the right side of the frame with a utility stand.
CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion
stub shaft can result in damage to the steering gear and/or damage
to the intermediate shaft. This damage may cause loss of steering
control which could result in personal injury.
5. Support the left side of the frame with a utility stand. Remove the transaxle mount and bracket. See
TRANSAXLE MOUNT & BRACKET .
6. Loosen the engine mount lower nuts. See appropriate REMOVAL & INSTALLATION article. Loosen
the right side frame bolts. Remove the left side frame bolts. Use the utility stand in order to lower left side
of the frame.
7. Position the drain pan under the transaxle. Remove the wiring harness connectors. Remove the case side
cover bolts. See Fig. 18 . Remove the case side cover pan (53). See Fig. 19 . Remove the case side cover
gasket (54). Remove the case side cover inner gasket (59).
8. Inspect the case side cover (53) for the following conditions:
Damaged or porous gasket sealing surfaces.
Damaged or porous casting surfaces.
Damaged or stripped bolt holes.
9. Inspect the case side cover gasket (54) and case side cover inner gasket (59) for damage. The gaskets are
reusable if they are NOT damaged. Clean the case side cover. Clean the case side cover gasket surfaces.
Toshiba
2003 Pontiac Aztek
Fig. 18: Identifying Case Side Cover Bolt Locations

Toshiba
2003 Pontiac Aztek
Fig. 19: Removing & Installing Case Side Cover Pan

Installation
1. Apply Transjel(tm) Lubricant (J-36850) to the case side cover "O" ring (59). See Fig. 19 . Install the "O"
ring (59) to the case side cover. Install the case side cover gasket (54).
2. Install the case side cover (53). Install the case side cover bolts. See Fig. 18 . Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Remove the drain pan from under the transaxle.
Toshiba
2003 Pontiac Aztek
3. Install the wiring harness connectors. Use the utility stand in order to raise the left side of the frame.
Install the NEW left side frame bolts. Install the NEW right side frame bolts. Install the engine mount
lower nuts.
4. Install the transaxle mount and bracket. See TRANSAXLE MOUNT & BRACKET . Tighten the bolts
to specification. See TORQUE SPECIFICATIONS . Lower the vehicle.
5. Remove the utility stand support from the right side of the frame. Remove the utility stand support from
the left side of the frame. Connect the catalytic converter pipe to the right (rear) exhaust manifold.
6. Install the intermediate shaft to the steering gear. See appropriate POWER RACK & PINION article in
STEERING.
CAUTION: When installing the intermediate shaft make sure that the shaft is
seated prior to pinch bolt installation. If the pinch bolt is inserted into
the coupling before shaft installation, the two mating shafts may
disengage. Disengagement of the two mating shafts will cause loss
of steering control which could result in personal injury.
7. Install the left drive axle to the transaxle. See appropriate AXLE SHAFTS article in
DRIVELINE/AXLES. Install the left lower ball joint to the left steering knuckle. See appropriate FRONT
article in SUSPENSION.
8. Install the wheel speed sensor harness connector. Install the left tie rod end to the steering knuckle. Install
the stabilizer shaft links to the lower control arms. See appropriate FRONT article in SUSPENSION.
9. Install the left engine splash shield. Install the left front tire and wheel. Lower the vehicle. Install the
engine mount struts. See appropriate REMOVAL & INSTALLATION article.
10. Remove the engine support fixture. Remove the throttle body air inlet duct. Connect the negative battery
cable.
11. Fill transaxle with appropriate fluid to proper level. See LUBRICATION . Inspect for fluid leaks.
Inspect for proper completion of the repairs. Inspect for fluid leaks.
CAUTION: DO NOT overfill the transaxle. Overfilling will result in foaming, loss
of fluid, and possible damage to the transaxle.
CONTROL VALVE BODY
Removal
1. Remove the case side cover. See CASE SIDE COVER . Remove the oil pump. See OIL PUMP .
Remove the valve body bolts (374-381 and 384). See Fig. 20 .
2. Remove the valve body (300) while keeping the spacer plate (370) with the transaxle. See Fig. 21 .
Remove the ball check valves (372 and 373) from the valve body. See Fig. 22 .
CAUTION: Carefully remove the valve body or the ball check valves will fall out.
Toshiba
2003 Pontiac Aztek
3. Remove the spacer plate (370) and gasket. See Fig. 23 . Remove the ball check valves (372) from the
case cover. See Fig. 24 . Inspect each check valve seat in the spacer plate (370) for excessive peening.
See Fig. 25 .
4. Place a ball check valve (372) on each seat and use a flashlight in order to look for visible light between
the valve and the seat. Inspect all components removed from the transaxle. See appropriate OVERHAUL
article.
Toshiba
2003 Pontiac Aztek
Fig. 20: Identifying Valve Body Bolts

Toshiba
2003 Pontiac Aztek
Fig. 21: Removing & Installing Control Valve Body Assembly

Toshiba
2003 Pontiac Aztek
Fig. 22: Locating Check Balls In Valve Body

Toshiba
2003 Pontiac Aztek
Fig. 23: Identifying Spacer Plate

Toshiba
2003 Pontiac Aztek
Fig. 24: Locating Check Balls In Case Cover

Toshiba
2003 Pontiac Aztek
Fig. 25: Inspecting Check Valve Seats In Spacer Plate

Installation
CAUTION: DO NOT use any type of grease to retain parts during the assembly of this
unit. Using greases other than the recommended assembly lube changes
the transaxle fluid characteristics. Using greases other than the
recommended assembly lube causes undesirable shift conditions and/or
filter clogging. Use Transjel(tm) Lubricant (J-36850) or equivalent during
the assembly of this unit.
Toshiba
2003 Pontiac Aztek
1. Install the ball check valves (372) into the case cover. See Fig. 24 . Use the Transjel(tm) lubricant to
retain the ball check valves in their proper locations. Install the gasket and the spacer plate (370). See Fig.
23 .
2. Install the ball check valves (372 and 373) into the valve body. See Fig. 22 . Use the Transjel(tm)
lubricant to retain the ball check valves in their proper locations.
3. Install the gasket (371) and the valve body (300). See Fig. 21 . Install the valve body bolts (374-381 and
384). See Fig. 20 . Tighten the valve body bolts to specification. See TORQUE SPECIFICATIONS .
CAUTION: DO NOT use impact type tools on the valve body or on the oil pump.
4. DO NOT use impact type tools on the valve body or on the oil pump. Install the oil pump. See OIL
PUMP . Install the case side cover. See CASE SIDE COVER .
FLUID FILLER TUBE
Removal
Remove the oil indicator from the filler tube. Remove the air cleaner assembly. Remove the retaining nut from
the EGR at the top of the filler tube. See Fig. 26 . Remove the lower retaining bolt at the base of the filler tube.
Remove the fluid filler tube.
Toshiba
2003 Pontiac Aztek
Fig. 26: Removing & Installing Fluid Filler Tube

Installation
CAUTION: DO NOT place the fluid filler tube seal on the fluid filler tube when
installing the tube or damage to the seal will result.
Install the fluid filler tube seal in the transaxle. See Fig. 27 . Position the fluid filler tube into the transaxle.
Install the fluid filler tube bracket bolt through the fluid filler tube bracket. See Fig. 26 . Tighten the fluid filler
Toshiba
2003 Pontiac Aztek
tube bracket bolt to specification. See TORQUE SPECIFICATIONS . At the top of the filler tube, install the
retaining nut to the filler tube the EGR at the top of the filler tube. Install the air cleaner assembly. Fill transaxle
with appropriate fluid to proper level. See LUBRICATION . Inspect for fluid leaks.
Fig. 27: Installing Fluid Filler Tube Seal

Toshiba
2003 Pontiac Aztek
FORWARD SERVO (FWD)
Removal
NOTE: This procedure is for FWD vehicles ONLY. The forward servo for AWD vehicles
is serviced with the transfer case removed, which MUST be serviced with the
transaxle removed from the vehicle. For transfer case replacement, see
appropriate REMOVAL & INSTALLATION article.
1. Install the engine support fixture. See appropriate REMOVAL & INSTALLATION article. Raise and
support the vehicle. Remove the stabilizer shaft. Remove the power steering gear heat shield. Remove the
power steering gear from the frame. See appropriate POWER RACK & PINION article in STEERING.
2. Use a strap in order to secure the power steering gear to the exhaust manifold. See appropriate POWER
RACK & PINION article in STEERING. Remove the power steering cooler line clamps from the frame.
Use wire in order to secure the power steering cooler line to an engine component.
3. Remove the engine mount nuts. See appropriate REMOVAL & INSTALLATION article. Remove the
transaxle mount nuts. Use a utility stand in order to support the frame front. Use a utility stand in order to
support the frame rear.
4. Remove the frame bolts. Use the utility stand in order to lower the frame rear for access to the forward
servo cover. Position a drain pan under the forward servo cover.
5. Remove the forward band servo cover bolts. Remove the forward servo cover. Remove the forward servo
cover "O" ring. Remove the servo piston assembly. Remove the servo spring. See Fig. 28 .
Toshiba
2003 Pontiac Aztek
Fig. 28: Removing & Installing Forward Servo

Installation
1. Install the servo spring. Install the servo piston assembly. Install the forward servo cover "O" ring. Install
the forward servo cover. See Fig. 28 .
2. Install the 3 forward servo cover attaching bolts. Tighten the forward servo cover attaching bolts to
specification. See TORQUE SPECIFICATIONS .
3. Remove the drain pan from under the forward servo cover. Use the utility stand in order to raise the frame
rear. Install the NEW frame bolts. Install the powertrain mounts to the frame. Install the transaxle mount
nuts. Install the engine mount nuts. See appropriate REMOVAL & INSTALLATION article.
4. Install the power steering gear to the frame. See appropriate POWER RACK & PINION article in
STEERING. Install the power steering gear heat shield. Install the stabilizer shaft.
5. Lower the vehicle. Remove the engine support fixture. Fill transaxle with appropriate fluid to proper
level. See LUBRICATION .
FORWARD SERVO (AWD)
Toshiba
2003 Pontiac Aztek
NOTE: Removal and installation of the transfer case while the transmission is in
vehicle may cause improper positioning of the park gear thrust bearing. If the
transfer case fasteners are tightened while the park gear thrust bearing is out of
position, the park gear thrust bearing, transmission, and/or the transfer case
will be damaged.
Removal
1. Remove the transaxle assembly. See appropriate OVERHAUL article.

2. Remove the transfer case from the transmission. See appropriate OVERHAUL article.
3. Remove the forward band servo cover bolts. See Fig. 28 .
4. Remove the forward servo cover.
5. Remove the forward servo cover "O" ring.
6. Remove the servo piston assembly.
7. Remove the servo spring.
Installation
1. Install the servo spring. See Fig. 28 .

2. Install the servo piston assembly.
3. Install the forward servo cover "O" ring.
4. Install the forward servo cover.
5. Install the transfer case. See appropriate OVERHAUL article.
6. Install the transaxle. See appropriate OVERHAUL article.
INPUT SPEED SENSOR
Removal
1. Remove the case side cover. See CASE SIDE COVER .

2. Disconnect the transaxle wiring harness. Remove the input speed sensor clip (441) from the case cover.
See Fig. 29 .
3. Remove the input speed sensor (440) from the case cover. Inspect the input speed sensor (440) for the
following conditions:
Damaged or missing magnet.
Damaged housing.
Bent or missing electrical terminals.
Damaged speed sensor clip (441).
Toshiba
2003 Pontiac Aztek
Fig. 29: Removing & Installing Input Shaft Speed Sensor

Installation
1. Install the input speed sensor (440) into the case cover. See Fig. 29 .
2. Install the input speed sensor clip (441) into the case cover.
3. Connect the transaxle wiring harness.
4. Install the case side cover. See CASE SIDE COVER .
OIL COOLER HOSES
CAUTION: Allow sufficient clearance around the transaxle oil cooler pipes and
Toshiba
2003 Pontiac Aztek
around the hoses to prevent damage or wear which may cause fluid loss.
Removal
1. Disconnect the transaxle oil cooler (TOC) outlet hose from top side of the radiator as follows:
A. Disengage the plastic cap from the quick connect fitting. Pull the plastic cap back along the pipe.
See Fig. 30 .
B. Hold one leg of the retaining clip.
C. Using a small pick-type tool or bent screwdriver, gently disengage the other end of the retaining
clip from the quick connect fitting.
D. Rotate the retaining clip out of the quick connect fitting. Remove the retaining clip completely.
E. Disconnect the cooler line from the quick connect fitting.
2. Raise and support the vehicle.
3. Remove the TOC hose retainer bolt. See Fig. 31 .
4. Position a drain pan below the oil cooler hoses.
5. Disconnect the TOC outlet hose from the transaxle. See Fig. 32 . Perform steps -D .
6. Disconnect the TOC inlet hose from the transaxle. See Fig. 32 . Perform steps -D .
7. Disconnect the TOC inlet hose from the radiator. See Fig. 33 . Perform steps -D .
8. Disconnect the TOC hoses from the radiator support retainer.
9. Remove the TOC hoses from the vehicle.
Toshiba
2003 Pontiac Aztek
Fig. 30: Removing Retaining Ring

Toshiba
2003 Pontiac Aztek
Fig. 31: Removing & Installing Oil Cooler Hoses At Transaxle

Toshiba
2003 Pontiac Aztek
Fig. 32: Removing & Installing Oil Cooler Hoses At Transaxle

Toshiba
2003 Pontiac Aztek
Fig. 33: Removing & Installing Oil Cooler Pipes At Radiator

Installation
NOTE: Allow sufficient clearance around the transaxle oil cooler pipes and around the
hoses to prevent damage or wear which may cause fluid loss.
1. Install the TOC hoses to the vehicle. See Fig. 33 .

2. Connect the TOC hoses to the radiator support retainer.
NOTE: Failure to properly install the retaining clip could cause the cooler line to
come loose and cause damage to vehicle components. DO NOT install the
retaining clip onto the fitting by pushing on the clip.
Toshiba
2003 Pontiac Aztek
3. Connect the TOC inlet hose to the radiator as follows:

A. Install the retaining clip into the quick connect fitting by using your thumb and forefinger. Insert
the retaining clip into one of the three fitting recesses. Ensure that the retaining clip is engaged in
all 3 slots. See Fig. 34 .
B. With one end of the retaining clip engaged in the connector fitting slot, use your thumb in order to
rotate the retaining clip around the connector fitting, until the retaining clip snaps into place.
C. Ensure that the 3 retaining clip ears are seen from inside the fitting and that the retaining clip moves
freely in the fitting slots.
NOTE: A distinct snap should be heard when assembling the cooler line to
the quick connect fitting. To ensure the cooler line is fully inserted
into the quick connect fitting, give the cooler line a gentle pull. DO
NOT use the plastic cap in order to install the cooler line into the
fitting.
D. Install the cooler line straight into the quick connect fitting until a click is either heard or felt.
E. Pull back gently on the cooler line in order to ensure that the cooler line is installed in the quick
connect fitting.
NOTE: Ensure the cooler line being installed has a plastic cap on the end
that connects to the quick connect fitting. If no plastic cap exists, or
the plastic cap is damaged, obtain a new cap. Install the cap on to the
cooler line prior to cooler line installation. DO NOT manually depress
the retaining clip when installing the plastic cap.
F. Snap the plastic cap onto the quick connect fitting.

G. Ensure that the plastic cap is fully seated against the fitting.
H. Ensure that no gap is present between the cap and the fitting.
I. Run the engine. Inspect the transmission oil cooling system for leaks.
J. Inspect the fluid levels. Add fluid if necessary.
4. Connect the TOC inlet hose to the transaxle. See Fig. 32 . Perform steps -I .
5. Connect the TOC outlet hose to the transaxle. See Fig. 32 . Perform steps -I .
6. Install the TOC hose retainer and the bolt. Tighten to specification. See TORQUE SPECIFICATIONS .
7. Lower the vehicle.
8. Connect the TOC outlet hose to the top side of the radiator. Perform steps -I .
9. Adjust the fluid level. See LUBRICATION .
Toshiba
2003 Pontiac Aztek
Fig. 34: Starting Retaining Ring Onto Quick Connect Fitting

OIL PRESSURE TEST PLUG
Removal
Remove the throttle body air inlet duct. Remove the pressure test hole plug (38). See Fig. 35 .
Toshiba
2003 Pontiac Aztek
Fig. 35: Removing & Installing Oil Pressure Test Plug

Installation
Apply sealant to the pressure test hole plug. Install the pressure test hole plug (38). See Fig. 35 . Tighten the
line pressure pipe plug to specification. See TORQUE SPECIFICATIONS . Install the throttle body air inlet
duct.
OIL PUMP
Removal
NOTE: DO NOT remove the 3 bolts which hold the pump together.
Remove the case side cover. See CASE SIDE COVER . Remove the oil pump bolts (205, 206 and 207). See
Toshiba
2003 Pontiac Aztek
Fig. 36 . Remove the oil pump from the valve body. See Fig. 37 . Clean and inspect the oil pump. See
appropriate OVERHAUL article.
Toshiba
2003 Pontiac Aztek
Fig. 36: Identifying Oil Pump Bolts

Toshiba
2003 Pontiac Aztek
Fig. 37: Removing & Installing Oil Pump Assembly

Installation
Install the oil pump to the valve body. See Fig. 37 . Install the oil pump bolts (205, 206 and 207). See Fig. 36 .
Tighten the oil pump bolts to specification. See TORQUE SPECIFICATIONS . Install the case side cover.
See CASE SIDE COVER .
OUTPUT SHAFT
NOTE: This procedure is for FWD vehicles ONLY. The output shaft for AWD vehicles is
serviced with the transfer case which MUST be serviced with the transaxle
removed from the vehicle. For transfer case replacement, see appropriate
Toshiba
2003 Pontiac Aztek
REMOVAL & INSTALLATION article.
Removal
1. Disconnect the left and right drive axles from the transaxle. See appropriate AXLE SHAFTS article in
DRIVELINE/AXLES. Remove the case extension housing. See CASE EXTENSION HOUSING .
Rotate the differential carrier until the end of the output shaft can be seen and the differential pinion shaft
is in a horizontal position. See Fig. 38 .
2. Place the Axle Removal Wedge (J-42562) between the end of the output shaft and the differential pinion
shaft. Using a hammer, hit the end of the axle removal wedge in order to compress the output shaft
compression ring and push the output shaft through the differential side gear.
3. Remove the differential carrier. Using snap ring pliers remove the compression ring from the output shaft.
See Fig. 39 . Be careful not to damage the bearing on the output shaft. See Fig. 41 .
4. Remove the output shaft through the left wheel opening. See Fig. 40 . Inspect the output shaft and the
bearing for the following:
A cracked or deformed bearing cage.
Damaged bushing journals.
Stripped splines.
A damaged retainer ring groove.
Toshiba
2003 Pontiac Aztek
Fig. 38: Removing Output Shaft

Toshiba
2003 Pontiac Aztek
Fig. 39: Removing Differential Carrier Assembly

Toshiba
2003 Pontiac Aztek
Fig. 40: Removing & Installing Output Shaft

Toshiba
2003 Pontiac Aztek
Fig. 41: Identifying Fourth Clutch Bearing

Installation
1. Install the drive axle retaining ring and the output shaft differential inboard snap ring onto the output
shaft. See Fig. 41 . Install the fourth clutch bearing onto the output shaft. See Fig. 41 .
2. Hold the front differential carrier in place and carefully install the output shaft into the transaxle through
the left wheel opening. See Fig. 40 .
3. Extend the output shaft through the differential side gear. Install the case extension housing. See CASE
EXTENSION HOUSING .
PRESSURE CONTROL SOLENOID
Removal
Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring harness. Remove the
pressure control solenoid (322). See Fig. 42 .
Toshiba
2003 Pontiac Aztek
Fig. 42: Removing & Installing Pressure Control Solenoid

Installation
Install the pressure control solenoid (322). See Fig. 42 . Connect the transaxle wiring harness. Install the case
side cover. See CASE SIDE COVER .
REVERSE SERVO
Removal
1. Remove the throttle body air inlet duct. Use a large flat-blade tool in order to depress the reverse servo
cover. See Fig. 43 .
Toshiba
2003 Pontiac Aztek
2. Use a small flat-blade tool in order to remove the retaining ring. See Fig. 44 . Use a small flat-blade tool
in order to pull the "O" ring seal out through the slot in the case. Use side cutting pliers in order to cut the
servo cover "O" ring seal.
3. Depress the reverse servo cover, grasp one end of the cut seal and pull the seal out of the servo cover.
4. Use a large flat-blade tool in order to depress the reverse servo cover, grasp one end of the cut seal and
pull the seal out of the servo cover.
5. Remove the reverse servo cover. See Fig. 44 . Remove the servo assembly. Remove the servo spring.
Fig. 43: Removing & Installing Reverse Servo Assembly Cover

Toshiba
2003 Pontiac Aztek
Fig. 44: Removing & Installing Reverse Servo Assembly

Installation
1. Raise the driver (left) side of the vehicle until it is higher than the passenger (right) differential side. This
ensures the reverse band is in the proper location.
NOTE: Failure to perform the following step may result in no reverse gear due to
the servo pin not aligning with the reverse band.
Toshiba
2003 Pontiac Aztek
2. Install the servo spring. See Fig. 44 . Install the servo assembly.
3. Install the reverse servo cover with new "O" ring seal. See Fig. 43 . Install the snap ring. Install the
throttle body air inlet duct.
SHIFT CABLE
Removal
1. Remove the throttle body air inlet duct. Use a flat-blade tool in order to remove the retaining clip from the
shift cable at the shift cable bracket. See Fig. 45 .
2. Use a large flat-blade tool in order to remove the shift cable from the manual control lever. See Fig. 46 .
Use pliers in order to depress the cable retainers.
3. Remove the shift cable from the shift cable bracket. Remove the knee bolster.
4. If the vehicle is equipped with a console shift, perform the following steps:
A. Remove the console trim plate. See appropriate SHIFT INTERLOCK SYSTEMS article.
B. Remove the transaxle shift cable from the floor shift control. See Fig. 47 .
5. If the vehicle is equipped with a column shift, perform the following steps:
A. Remove the retaining clip from the shift cable at steering column. See Fig. 48 .
B. Use a flat-blade tool in order to remove the automatic transaxle range selector cable from the
column control lever.
C. Remove the shift cable from the column control lever.
6. Remove the shift cable through the hole in the cowl. See Fig. 49 .
Toshiba
2003 Pontiac Aztek
Fig. 45: Removing & Installing Shift Cable At Transaxle Bracket (Typical)
Toshiba
2003 Pontiac Aztek
Fig. 46: Removing & Installing Shift Cable At Externally Mounted PNP Switch (If Equipped)
Toshiba
2003 Pontiac Aztek
Fig. 47: Removing & Installing Shift Cable At Shift Control

Toshiba
2003 Pontiac Aztek
Fig. 48: Removing & Installing Retaining Clip

Toshiba
2003 Pontiac Aztek
Fig. 49: Locating Shift Cable Pass-Through

Installation
1. Properly route the shift cable through the engine compartment. See Fig. 50 . Install the shift cable through
the cowl. See Fig. 49 .
2. If the vehicle is equipped with a column shift, perform the following steps:
A. Install the shift cable to the steering column bracket.
B. Install the retaining clip to the shift cable. See Fig. 48 .
C. Install the shift cable to the column control lever.
3. If the vehicle is equipped with a console shift, perform the following steps:
A. Install the transaxle shift cable to the floor shift control. See Fig. 47 .
B. Install the console trim plate. See appropriate SHIFT INTERLOCK SYSTEMS article.
4. Install the knee bolster. Install the shift cable to the shift cable bracket. Install the shift cable to the PNP
switch lever. Install the retaining clip to the shift cable. See Fig. 46 .
5. Adjust the shift cable. See SHIFT CABLE under ADJUSTMENTS. Install the throttle body air inlet
duct.
Toshiba
2003 Pontiac Aztek
Fig. 50: Identifying Shift Cable Routing

TCC PULSE WIDTH MODULATION SOLENOID
Removal
1. Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring harness.
2. Remove the TCC pulse width modulation solenoid (334). See Fig. 51 .
Toshiba
2003 Pontiac Aztek
Fig. 51: Exploded View Of TCC Pulse Width Modulation Solenoid

Installation
1. Install the TCC PWM solenoid (334). See Fig. 51 . Connect the transaxle wiring harness.
2. Install the case side cover. See CASE SIDE COVER .
TFP MANUAL VALVE POSITION SWITCH
Removal
1. Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring harness.
2. Remove the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve
Toshiba
2003 Pontiac Aztek
position switch to the control valve body (300). See Fig. 52 .

3. Carefully remove the fluid pressure manual valve position switch. Handle the switch carefully, the fluid
pressure manual valve position switch is very delicate. Inspect the fluid pressure manual valve position
switch (395) for the following conditions:
Damaged electrical connector terminals.
Damaged seals.
Damaged switch membranes.
Debris on the switch membranes.
NOTE: When removing the TFP switch handle the switch carefully, the fluid
pressure manual valve position switch is very delicate.
Toshiba
2003 Pontiac Aztek
Fig. 52: Removing & Installing Transmission Fluid Pressure Manual Valve Position Switch
Installation
1. Carefully install the fluid pressure manual valve position switch. Handle the switch carefully, the fluid
pressure manual valve position switch is very delicate. See Fig. 52 .
2. Install the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve
position switch to the control valve body (300). Tighten the control valve body bolts (375, 379 and 381)
to specification. See TORQUE SPECIFICATIONS .
3. Connect the transaxle wiring harness. Install the case side cover. See CASE SIDE COVER .
Toshiba
2003 Pontiac Aztek
THERMO ELEMENT
Removal
1. Remove the oil pan. See DRAINING & REFILLING under LUBRICATION.
2. Remove the thermo element pins and washers (120 and 123). See Fig. 53 .
3. Remove the thermo element (121) and the thermo element plate (122).
Fig. 53: Removing & Installing Thermo Element

Installation
Toshiba
2003 Pontiac Aztek
1. Use the Thermo Element Height Gage (J-34094-A) to set the middle thermo pin (123). See Fig. 54 .
Install the new thermo element plate (122). Install the pin and washer (120).
2. Use the thermo element height gage to set the height of the pin and washer (120) furthest from the
accumulator. Use the thermo element height gage to set the height of the second pin and washer (120).
3. Carefully install the thermo element (121) between the 2 pin and washers (120). The "V" in the thermo
element (121) must contact the thermo element plate (122). Install the oil pan. See DRAINING &
REFILLING under LUBRICATION. Fill transaxle with appropriate fluid to proper level. See
LUBRICATION .
Fig. 54: Identifying Thermo Element Height Gage

TRANSAXLE BRACE
Removal
Disconnect the negative battery cable. Raise and support the vehicle. Remove the right front tire and wheel.
Remove the right engine splash shield. Remove the transaxle brace bolts. See Fig. 55 . Remove the transaxle
brace.
Toshiba
2003 Pontiac Aztek
Fig. 55: Removing & Installing Transaxle Brace

Installation
Position the transaxle brace to transaxle and engine. Hand start the bolts to the engine. Hand start the bolts to
the transaxle. Install the transaxle brace bolts to the engine. Install the transaxle brace bolts to the transaxle. See
Fig. 55 . Tighten the transaxle brace bolts to the transaxle to specification. See TORQUE
SPECIFICATIONS . Tighten the transaxle brace bolts to the engine to specification. Install the right engine
splash shield. Install the right front tire and wheel. Lower the vehicle. Connect the negative battery cable.
TRANSAXLE MOUNT & BRACKET
Removal
1. Raise and support the vehicle. Remove the left front tire and wheel. Remove the left inner splash shield.
2. Use a utility stand with a block of wood in order to support the transaxle. Remove the transaxle mount
Toshiba
2003 Pontiac Aztek
upper nuts. See Fig. 56 .

3. Remove the transaxle bracket to transaxle mount upper nuts. See Fig. 56 . Remove the transaxle mount
bracket bolts. Remove the transaxle mount bracket. See Fig. 57 .
4. Remove the transaxle mount lower nuts to the transaxle mount frame bracket. Remove the transaxle
mount from the transaxle mount frame bracket.
Fig. 56: Removing & Installing Transaxle Upper Mount Nuts

Toshiba
2003 Pontiac Aztek
Fig. 57: Removing & Installing Transaxle Bracket Bolts

Installation
1. Install the transaxle mount to the transaxle mount frame bracket. Install the transaxle mount lower nuts to
the transaxle mount frame bracket. Tighten transaxle mount lower nuts to specification. See TORQUE
SPECIFICATIONS .
2. Position the transaxle mount to the frame. Install the transaxle mount bracket bolts. See Fig. 57 . Start
with the forward lower bolt and work clockwise to tighten the transaxle bracket bolts to specification. See
TORQUE SPECIFICATIONS .
3. Remove the utility stand. Install the transaxle mount upper nuts. See Fig. 56 . Tighten the transaxle mount
upper nuts to specification. See TORQUE SPECIFICATIONS .
4. Install the left engine splash shield. Install the left front tire and wheel. Lower the vehicle.
TRANSAXLE VENT
Removal
Remove the throttle body air inlet duct. Use a hammer and a chisel in order to raise the transaxle vent seat off of
the transaxle. See Fig. 58 . Use a flat-blade tool in order to pry the transaxle vent (37) out of the transaxle.
Toshiba
2003 Pontiac Aztek
Fig. 58: Removing & Installing Transaxle Vent Tube

Installation
Use a small hammer and a flat-blade tool and tap down on the transaxle vent seat in order to install the transaxle
vent (37). See Fig. 58 . Install the air cleaner intake duct.
VEHICLE SPEED SENSOR
Removal
NOTE: Handle the vehicle speed sensor (10) carefully.
Raise and support the vehicle. Remove the right front tire and wheel assembly. Remove the right engine splash
Toshiba
2003 Pontiac Aztek
shield. Remove the vehicle speed sensor wiring harness connector. Remove the vehicle speed sensor bolt (9).
See Fig. 59 . Remove the vehicle speed sensor (10) from the extension case. Remove the "O" ring (11) from the
vehicle speed sensor (10). See Fig. 60 . Inspect the vehicle speed sensor and "O" ring seal for the following:
Damaged connector.
Cracked housing.
Signs of rotor damage.
Cuts or nicks on the "O" ring seal (11).
Fig. 59: Removing & Installing Vehicle Speed Sensor

Toshiba
2003 Pontiac Aztek
Fig. 60: Removing & Installing Vehicle Speed Sensor "O" ring
Installation
Install the "O" ring (11) to the vehicle speed sensor (10). See Fig. 60 . Install the vehicle speed sensor (10) to
the extension case. Install the vehicle speed sensor bolt (9). See Fig. 59 . Tighten the vehicle speed sensor bolt
(9) to specification. See TORQUE SPECIFICATIONS . Install the vehicle speed sensor wiring harness
connector. Install the right front tire and wheel assembly. Lower the vehicle.
WIRING HARNESS
Removal
Remove the case side cover. See CASE SIDE COVER . Use a small flat-blade tool in order to remove the
wiring harness from the solenoid valve(s), TFP manual valve position switch and/or the temperature sensor. See
Fig. 61 . Remove the wiring harness. Remove the clips retaining the solenoid(s).
Toshiba
2003 Pontiac Aztek
Fig. 61: Removing & Installing Wiring Harness

Installation
Connect the wiring harness. See Fig. 61 . Install the wiring harness to the solenoid valve(s), TFP manual valve
position switch and/or the temperature sensor. Install the case side cover. See CASE SIDE COVER .
1-2 SHIFT SOLENOID VALVE
Removal
Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring harness. Remove the
1-2 shift solenoid (315A). See Fig. 62 .
Toshiba
2003 Pontiac Aztek
Fig. 62: Exploded View Of 1-2 Shift Solenoid Valve Components

Installation
Install the 1-2 shift solenoid (315A). See Fig. 62 . Connect the transaxle wiring harness. Install the case side
cover. See CASE SIDE COVER .
2-3 SHIFT SOLENOID VALVE
Removal
Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring harness. Using a
Toshiba
2003 Pontiac Aztek
small screwdriver or pick, remove the 2-3 shift solenoid valve retainer (314C) from the control valve body
(301). See Fig. 63 . Remove the 2-3 shift solenoid (315B). Remove the "O" ring seal (316) from the 2-3 shift
solenoid valve (315B) ONLY if it is damaged.
Fig. 63: Exploded View Of 2-3 Shift Solenoid Valve Components

Installation
Install a new "O" ring seal (316) onto the 2-3 shift solenoid valve (315B) if the "O" ring was removed. Install
the 2-3 shift solenoid (315B). See Fig. 63 . Install the 2-3 shift solenoid valve retainer (314C) into the control
valve body (301). Connect the transaxle wiring harness. Install the case side cover. See CASE SIDE COVER .
TORQUE SPECIFICATIONS
Toshiba
2003 Pontiac Aztek
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Brace-To-Engine Bolt 46 (62)
Brace-To-Transaxle Bolt 32 (43)
Case Extension Housing Bolt 27 (37)
Engine Mount Strut 35 (48)
Manual Control Lever Nut 15 (20)
Manual 2-1 Band Servo Cover Bolt 17 (23)
Oil Cooler Hose Clip Bolt 18 (24)
Oil Cooler Hose Fitting 17 (23)
Oil Cooler Pipe Fitting 33 (45)
Oil Pump Bolt (2)
M6 X 1.0 X 95 (206) 12 (16)
PNP Switch Mounting Bolt 23 (31)
Transaxle Bracket Bolt 70 (95)
Transaxle Mount Upper Nut 35 (48)
Valve Body Bolts (1)
M6 X 1.0 X 95 12 (16)
M8 X 1.25 X 90 18 (24)
INCH Lbs. (N.m)
Accumulator Bolt 97 (11)
Fluid Filler Tube Bracket Bolt 115 (13)
Forward Servo Cover Attaching Bolt 97 (11)
Line Pressure Pipe Plug 97 (11)
Oil Cooler Pipe Clip Bolt 27 (3)
Oil Pan Bolt 124 (14)
Oil Pump Bolts (2)
M6 X 1.0 X 20 (205) 70 (8)
M6 X 1.0 X 85 (207) 106 (12)
Valve Body Bolts (1)
M6 X 1.0 X 20 70 (8)
M6 X 1.0 X 30, M6 X 1.0 X 45, M6 X 1.0 X 60 & M6 X 1.0 X 65 106 (12)
M6 X 1.0 X 55, M6 X 1.0 X 85 & M6 X 1.0 X 95 97 (11)
Vehicle Speed Sensor Bolt 97 (11)
(1) See Fig. 20 .
(2) See Fig. 36 .
Toshiba

Auto Trans Service

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Auto Trans Service

Hochgeladen von

Copyright:

Verfügbare Formate

2003 Pontiac Aztek

2003 AUTOMATIC TRANSMISSIONS Servicing - Aztek & Rendezvous

2003 AUTOMATIC TRANSMISSIONS

Servicing - Aztek & Rendezvous

Fig. 1: Locating Transaxle ID Plate & SRTA Plate Information

OIL PAN GASKET

Fig. 2: Identifying Oil Pan Gasket (Hydra-Matic 4T65-E)

CHECKING FLUID LEVEL & CONDITION

TRANSAXLE FLUID CAPACITIES (1)

DRAINING & REFILLING

Inspect for clutch facing material.

Inspect for rubber particles.

Inspect for engine coolant.

CAUTION: DO NOT overfill the transaxle. Overfilling of the transaxle causes

Fig. 3: Removing & Installing Oil Pan & Filter

Fig. 4: Installing Oil Filter Seal

Fig. 5: Inspecting Oil Pan Flange

Fig. 6: Identifying Conical Washers

OIL COOLER FLUSHING

CAUTION: Flushing Solution (J-35944-22) is environmentally safe, yet powerful

Fig. 7: Identifying Flushing Equipment

Fig. 8: Connecting Flushing Equipment

Fig. 9: Flushing Oil Cooling System

Fig. 10: Capturing Fluid Discharge

OIL COOLER FLOW TEST

WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system.

Fig. 11: Adjusting Shift Cable (1 Of 2)

Fig. 12: Adjusting Shift Cable (2 Of 2)

REMOVAL & INSTALLATION

WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system.

CAUTION: When battery is disconnected, vehicle computer and memory systems

ACCUMULATOR & 2-1 MANUAL SERVO

Fig. 14: Removing & Installing Lube Oil Pipe

CASE EXTENSION HOUSING

Damaged or porous sealing surface for the vehicle speed sensor.

Damaged or porous sealing surface for the case extension housing.

Damaged or worn differential carrier bushing or output shaft bearing.

Damaged bolt holes.

Inspect the drive axle seal and replace if necessary.

Fig. 17: Removing & Installing Case Extension

WARNING: DO NOT overfill the transaxle. Overfilling of the transaxle causes

CASE SIDE COVER

Damaged or porous casting surfaces.

Damaged or stripped bolt holes.

Fig. 18: Identifying Case Side Cover Bolt Locations

Fig. 19: Removing & Installing Case Side Cover Pan

CONTROL VALVE BODY

Fig. 20: Identifying Valve Body Bolts

Fig. 21: Removing & Installing Control Valve Body Assembly

Fig. 22: Locating Check Balls In Valve Body

Fig. 23: Identifying Spacer Plate

Fig. 24: Locating Check Balls In Case Cover

Fig. 25: Inspecting Check Valve Seats In Spacer Plate

FLUID FILLER TUBE

Fig. 26: Removing & Installing Fluid Filler Tube

Fig. 27: Installing Fluid Filler Tube Seal

FORWARD SERVO (FWD)

Fig. 28: Removing & Installing Forward Servo

FORWARD SERVO (AWD)

1. Remove the transaxle assembly. See appropriate OVERHAUL article.

1. Install the servo spring. See Fig. 28 .

INPUT SPEED SENSOR

1. Remove the case side cover. See CASE SIDE COVER .

Bent or missing electrical terminals.