1 copyright © 2007 general motors corporation. all rights reserved

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Copyright © 2007 General Motors Corporation. All Rights Reserved.

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Transmissions New & Updates: 6T40/45

17440.12D

Welcome to

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The material contained in

this course component

was accurate and current

at the time of course

development

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www.gmtraining.com

Web Site

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Question 1

In which of the following regions is your dealership located?

A. Atlanta

B. Chicago

C. Dallas

D. Los Angeles

E. New York

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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.

Course Goal

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¨ 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

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¨ Describe the Control Solenoid Valve & Transmission Control Module Assembly Cleaning procedure

¨ Describe the Service Fast Learn Adapts procedure

¨ Describe the fluid checking procedure

Session Objectives cont.

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¨ 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 Objectives

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¨ Applications

¨ Introduction to 6T40

¨ Towing 6T40-equipped vehicle

¨ Overview of Components

Module 1 Topics

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¨ Chevrolet Malibu

¨ Saturn AURA

¨ Pontiac G6

6T40/45 Applications

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6T40 Trans. ID Info. (Fill-in-the-blanks)

1.

2.

3.

4.

5.

6.

7.

8.

9.

Code for A/TModel YearModel for Trans.

Num. seq. @ 0001

Trans. Family

Plant Source Code

Calendar Year

Julian Date

Shift/Line (A/B)

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6T40/45 Automatic Transmission

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6T40/45 Design Features

15Fill-in-the-Blanks Exercise

Hydra-Matic 6T40/45 6-Speed Automatic

Gears: Ratios: 1st 2nd 3rd 4th 5th 6th Reverse Effective Final Drive

4.582.961.911.451.000.752.94

6T40 = 3.176T45 = 3.87

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Which gear is the 1:1 gear ratio

in the 6T40?

Question

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¨ Towing w/Recreational Vehicle

¨ Towing a Trailer

– Dinghy

– Dolly

Towing Types

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¨ Towing capacity

¨ Towing distance

¨ Towing equipment

¨ Vehicle readiness

Tow Vehicle Considerations

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Dinghy Towing

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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.

NOTICE:

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Dinghy Towing – from the rear

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Recreational Towing – Dolly Towing

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

CAUTION

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¨ Gear-Type Fluid Pump Assembly

¨ Pressure Tap & Oil Level Plug

¨ Drain Plug

¨ Apply Components

¨ Planetary Gearsets

6T40 Components

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¨ Torque Converter

¨ Fluid Level Control Valve

¨ Control Solenoid (w/Body and TCM) Valve Assembly

¨ Drive Link Assembly

6T40 Components cont.

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Fluid Pump Assembly

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¨ Transmission Overheating

¨ Loss of Drive

¨ High or Low Line Pressure

¨ Slipping Clutch or Harsh Apply

Pump Related Diagnostic Tips

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Pressure Tap & Oil Level Plug

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Drain Plug

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Apply Components

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Planetary Gearsets

Planetary Gearsetsassembled

Planetary Gearsetsdisassembled

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Torque Converter Sub-assemblies

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

Tech Tip:

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Fluid Level Control Valve

Fluid level control valve

(inside transmission)

Fluid level control valve

(outside transmission)

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Control Solenoid (w/Body and TCM) Valve Assembly

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Bottom of Solenoid Assembly

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Solenoid Assembly 14-Way Connector

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Drive Link Assembly

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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

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Posttest Question 1

The purpose of the Fluid Level Control Valve is to control fluid level in the ___________.

A. Torque Converter

B. Control Solenoid

C. Control Valve Case

D. Control Valve Cover Assembly

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Posttest Question 2

How many shift solenoids are there

in the 6T40?

A. 1

B. 2

C. 3

D. 4

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Posttest Question 3

When dinghy towing, the vehicle should be run at the beginning of each day and at each RV fuel stop for about ________ minutes.

A. 5

B. 10

C. 15

D. 30

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Posttest Question 4

How many Planetary Gearsets are used in the 6T40?

A. 1

B. 2

C. 3

D. 4

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Posttest Question 5

Which engine is used for the first application of the 6T40?

A. 2.2L

B. 2.4L

C. 3.4L

D. 3.6L

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¨ 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

Module 2 Objectives

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Control Valve Body Cover

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Cover & Gasket

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Connector Hole Seal

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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.

Tech Tip:

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Solenoid Assembly & Filter Plate

Solenoid Assembly Solenoid Assembly Filter Plate

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Output Speed Sensor (OSS)

OSS – possible cablecrushed

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Input Speed Sensor (ISS)

Possible cable crushed

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¨ 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

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¨ Restart engine & operate vehicle based on criteria

¨ Observe if DTC(s) have run & passed

Control Solenoid Valve & TCM Assembly Cleaning cont.

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Control Solenoid Valve & TCM Solenoid Performance Test

Bolting DT-48616to Solenoid

DT-48616 TorqueSequence

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Control Solenoid (w/Body & TCM) Valve Assembly Solenoid Performance

Test Block to Component Identification

COMPONENT PORT ON

TEST BLOCK Key ON, Engine

OFF Normal State

PC Solenoid 2 F No PSI flow to

gauge

PC Solenoid 3 G Full PSI flow to

gauge

PC Solenoid 4 B No PSI flow to

gauge

PC Solenoid 5 C No PSI flow to

gauge

Shift Solenoid D Full PSI flow to

gauge

Line Pressure Control Solenoid

A Full PSI flow to

gauge

TCC PC Solenoid E No PSI flow to

gauge

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Control Solenoid Valve & TCM Solenoid Performance Test

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

CAUTION

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Control Solenoid Valve & TCM Solenoid Performance Test cont.

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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.

CAUTION

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¨ 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

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¨ Block drive wheels

¨ Apply parking brake

¨ Apply service brake

Service Fast Learn Adapts Procedure Conditions

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¨ 0% throttle / No RPM control

¨ 70º–100ºC (158º–212ºF) TFT

¨ Gear selector cycled 3X from P to R

Service Fast Learn Adapts Procedure Conditions cont.

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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.

Tech Tip:

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¨ PARK

Service Fast Learn Adapts Steps

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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.

CAUTION

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¨ PARK

¨ DRIVE

Service Fast Learn Adapts Steps cont.

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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.

CAUTION

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¨ PARK

¨ DRIVE

¨ REVERSE

Service Fast Learn Adapts Steps cont.

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¨ 70–100ºC (158–212ºF) TFT

¨ Proper function of brakes & brake switch

¨ Verify no active DTCs

¨ Closed throttle & engine RPM > 1500 RPM

Troubleshooting Tips

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¨ P / N switch adjusted & functioning

¨ Line pressure provides 1000 kPa (145 psi)

¨ Vehicle not moving or vibrating

Troubleshooting Tips cont.

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Manual Shift Detent w/Shaft Position Switch Lever Assembly

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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

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Posttest Question 6

How many inputs are there from the IMS to the TCM?

A. 1

B. 2

C. 4

D. 5

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Posttest Question 7

The Input Speed Sensor reluctor wheel is a part of the ______ clutch housing.

A. 3-5-R

B. 1-2-3-4

C. 4-5-6

D. Low & Reverse

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Posttest Question 8

To successfully complete the Service Fast Learn Adapts procedure, the throttle position must be ___ percent.

A. 0

B. 10

C. 15

D. 25

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Posttest Question 9

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 _______________.

A. clean & synchronize the solenoids

B. validate the shift solenoids in the TCM

C. learn individual clutch characteristics

D. reset & communicate with the ECM

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¨ Apply fluid checking procedure for the 6T40

¨ Describe temperature requirements

Module 3 Objectives

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6T40 Fluid Capacity Specifications

Specification Application Metric English

Valve Body Cover Removal–Approximate Capacity

5.0-7.0 liters

5.3-7.4 quarts

Fluid Change–Drain Plug -Approximate Capacity

4.0-6.0 liters

4.2- 6.3 quarts

Overhaul - Approximate Capacity

7.0-9.0 liters

7.4-9.5 quarts

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¨ 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

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¨ 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

Transmission Fluid Check cont.

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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

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¨ 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

Transmission Fluid Check cont.

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¨ Vehicle MUST be level

¨ Engine MUST be running

¨ Shift lever MUST be in PARK

Raise Vehicle

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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.

Tech Tip

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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.

IMPORTANT

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

Tech Tip

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Transmission Fluid

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Question 2

What is the proper temperature range for checking the fluid level in a 6T40/45?

A. 70º–90ºC (158°-194°F)

B. 80º–100ºC (176°-212°F)

C. 85º–95ºC (185°-203°F)

D. 95º–105ºC (203°- 221°F)

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Was the temperature in the video adequate to check the fluid level?

Question

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Transmission Fluid Temperature

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It is not necessary to get the fluid level all the way up to the maximum mark.

Anywhere within the crosshatch band is acceptable.

Tech Tip

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Module 3 Summary

¨ Applied fluid checking procedure for the 6T40

¨ Described temperature requirements

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Posttest Question 10

Which gear should the vehicle be driven in to bring the temperature within proper fluid checking range?

A. 1st

B. 2nd

C. 4th

D. Reverse

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To Obtain Posttest ResultsTo Obtain Posttest Results

After 5 Business Days go to:¨ www.gmtraining.com¨ Select “Training Records” from menu¨ Select “View Your Training Records”

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Transmissions New & Updates: 6T40/45

17440.12D

Thank you for attending

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Copyright © 2007 General Motors Corporation. All Rights Reserved.