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#03-07-30-025: Info - 2004 Model Year Changes for
4T40E and 4T45E Transmissions - (Jun 17, 2003)
Subject:

2004 Model Year Changes for 4T40E and 4T45E
Transmissions

Models:

2004 Chevrolet Cavalier, Classic, Malibu
2004 Oldsmobile Alero
2004 Pontiac Grand Am, Sunfire

The purpose of this bulletin is to introduce new changes for the 2004 model year 4T40E and
4T45E transmissions.

Electronic Range Selector Mode Models (Malibu)
The electronic range selector mode has the following new DTCs:
• P0815 - Upshift Switch Circuit
• P0816 - Downshift Switch Circuit
• P0826 - Up and Down Shift Switch Circuit
• P0876 - Up and Down Shift Switch Performance - Range Switch Not in D3
• P1877 - Up and Down Shift Switch Performance - Range Switch in D3

New Spacer Plate for Electronic Range Selector Mode Models (Malibu)

The new spacer plate has one (1) notch for TAP models and two (2) notches for all other
models.

New Hydrophobic Filter/Vent and Filler Cap with Case Baffle

A new hydrophobic filter/vent and filler cap (ILL #52) with case baffle (3) has been added to
prevent transaxle splash oil from leaking through the vent. The cap will be two different colors:
red and black. The red cap is only used for the Malibu models and the black cap is for all other
applications, forward and back. Referring to the graphic above, the top cap (1) is for 2003 and
prior and the bottom cap (2) is for 2004.

Valve Body Assembly, TCC Control Valve

The valve body assembly, TCC control valve (ILL #334) is larger in diameter and the material
changed from anodized aluminum to steel. It will not service past models.

Decontented Transmission Fluid Pressure (TFP)

Three switches have been eliminated. The three switches that remain are: release, drive and
reverse. The color of the plastic has changed from black to gray.
Two DTCs were also removed -- P1815 Transmission Fluid Pressure (TFP) Valve Position SwitchStart in Wrong Range and P1817 Transmission Fluid Pressure (TFP) Valve Position SwitchReverse with Drive Ratio. In the graphic above, the switch (1) on the left is the 2003 and prior
switch with the black color base. The switch on the right (2) is the 2004 switch with a gray color
base.

New NSBU Switch

A new NSBU switch with one large connector replaces the switch with two connectors. In the
graphic, the two connectors (1) are for 2003 and prior while the one large connector (2) is for
2004.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that
may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the
equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin
applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.


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