This procedure addresses a kickdown cable replacement request for a 2023 Chevrolet Bolt EUV. However, this electric vehicle uses a single-speed reduction gear transmission with no kickdown cable, as it has no multi-speed automatic transmission requiring throttle-based downshifting.

Warnings

Tools required

Parts

• Reduction gear oil seal (if applicable) × 1 — Use OEM specification
• Drain plug washer × 1 — GM 24236107 or equivalent
• Transmission pan gasket (if replacing) × 1 — Use OEM specification

Fluids

• ACDelco Dexron VI ATF — 13.5 qt

Preparation

1. Verify the actual customer concern and symptoms, as kickdown cables do not exist on this vehicle
2. Connect diagnostic scan tool and retrieve any DTCs related to throttle position, motor control, or drive unit
3. Perform high voltage system lockout/tagout procedure per GM service manual section 9B
4. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
5. Raise vehicle on lift and secure with jack stands rated for minimum 5000 lbs
6. Remove engine undervehicle splash shields
7. Allow drive unit to cool to ambient temperature if vehicle was recently driven

Procedure

1. 1

   Inspect Throttle Pedal Position Sensor
   Since there is no kickdown cable, verify throttle pedal position sensor operation. With scan tool connected, observe throttle position percentage while slowly depressing accelerator pedal. Value should increase smoothly from 0% to 100% without jumps or dropouts. Check connector at pedal assembly for corrosion or loose pins.
2. 2

   Test Drive Unit Communication
   Using scan tool, verify communication with drive unit control module. Check for DTCs related to motor position sensor, resolver, or inverter faults. Document all codes and freeze frame data before clearing.
3. 3

   Drain Reduction Gear Unit Fluid
   Position drain pan under reduction gear unit. Remove drain plug from bottom of drive unit housing and allow fluid to drain completely (approximately 3.5 quarts). Inspect fluid for metal particles, discoloration, or burning smell which would indicate internal drive unit damage. Install new crush washer on drain plug.
   ⚠Fluid may be hot if vehicle was recently operated. Allow adequate cooling time.
   Torque spec

   Drain Plug34 Nm (25 lb-ft)
4. 4

   Remove Drive Unit Sensors
   Disconnect electrical connectors from motor position sensor and any speed sensors on the drive unit. Remove sensor mounting bolts and carefully extract sensors. Inspect sensor faces and wiring for damage or contamination.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
5. 5

   Inspect Drive Unit Mounting
   Check all drive unit mounting bolts for proper torque and any signs of movement or wear in mounting bushings. Excessive movement could cause symptoms similar to transmission slippage that might be mistaken for kickdown cable issues.
   Torque spec

   Mounting Bolts61 Nm (45 lb-ft)
6. 6

   Remove and Inspect Transmission Pan (If Applicable)
   If reduction gear unit has a serviceable pan, remove pan bolts in criss-cross pattern starting from the center outward. Lower pan carefully and inspect for metal debris or clutch material. Clean pan and magnet thoroughly. Inspect pan gasket sealing surface for damage.
   ⚠Some residual fluid will drain when pan is removed. Ensure drain pan is positioned to catch spillage.
   Torque spec

   Pan Bolts16 Nm (12 lb-ft)
7. 7

   Inspect Internal Components (If Accessible)
   With pan removed, visually inspect reduction gear internal components for unusual wear, scoring, or damage. Check parking pawl operation if visible. Look for any foreign material or excessive metal particles on magnet.
8. 8

   Reinstall Sensors and Pan
   Install new pan gasket if removed. Position pan and install bolts finger-tight, then torque in criss-cross pattern from center outward. Reinstall motor position sensors with new O-rings if equipped, torquing sensor bolts to specification.
   Torque spec

   Pan Bolts16 Nm (12 lb-ft)

   Sensor Bolts11 Nm (8 lb-ft)
9. 9

   Refill Reduction Gear Fluid
   Remove fill plug from side of drive unit. Using fluid pump, fill reduction gear unit with ACDelco Dexron VI ATF until fluid begins to drain from fill hole (approximately 3.5 quarts for drain and fill, up to 13.5 quarts if completely dry). Install fill plug with proper torque.
   Torque spec

   Fill Plug34 Nm (25 lb-ft)
10. 10

    Perform System Relearn
    Using scan tool, perform drive unit relearn procedure and throttle position sensor calibration per GM service programming system. Clear any DTCs that were set during disassembly. Verify no new codes are present.

Reassembly

1. Reinstall engine undervehicle splash shields
2. Reconnect 12V auxiliary battery negative terminal
3. Remove high voltage lockout devices and restore high voltage system per GM procedures
4. Lower vehicle from lift
5. Verify all tools and parts have been removed from engine compartment and undercarriage

Verification

• With scan tool connected, verify throttle position sensor reads 0% at rest and reaches 100% at full pedal depression with smooth progression
• Start vehicle and verify no warning lights or DTCs are present
• Perform test drive and verify smooth acceleration without hesitation or jerking
• Check for any fluid leaks from drain plug, fill plug, or transmission pan
• Verify reduction gear fluid level is correct by checking that fluid drains from fill hole when plug is removed with vehicle level
• Document findings and explain to customer that vehicle has no kickdown cable and describe actual repairs performed

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