CHEVROLET AVEO 2002 Service Repair Manual

TRANSMISSION GENERAL SPECIFICATIONS
Transmission General Specifications
Washer Thickness
Shim Thickness
Stator Shaft Bolts25 N.m18 lb ft
TCM Retaining Bolts5 N.m44 lb in
Torque Converter Bolts45 N.m43 lb ft
Transaxle Apply Clamp Bolt5.4 N.m48 lb in
Transaxle Case Plate Bolt9.8 N.m87 lb in
Transaxle Housing Bolts29 N.m22 lb ft
Transaxle Rear Cover Bolts25 N.m18 lb ft
Unions25 N.m18 lb ft
Upper Transaxle Mounting Bracket Bolts60 N.m44 lb ft
Upper Transaxle-to-Engine Mounting Bolts73 N.m54 lb ft
Valve Body Bolts11 N.m97 lb in
Application
Specification
MetricEnglish
MakerAISIN
Type or Model81-40LE
Gear Ratio - 1st2.875:1
Gear Ratio - 2nd1.568:1
Gear Ratio - 3rd1.000:1
Gear Ratio - 4th0.697:1
Reverse2.300:1
Final Drive Ratio3.750:1
Oil Capacity5.6L5.9 qt
Transmission Fluid Type
T-IV Automatic Transmission Fluid (GM
Part No. U.S. 88900925, in Canada
22689186)
MetricEnglish
0.95 mm0.0374 in
1 mm0.0394 in
1.05 mm0.0413 in
1.1 mm0.0433 in
1.15 mm0.0453 in
1.2 mm0.0472 in
Specification

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

Adjuster Shim Thickness
ApplicationMetricEnglish
Mark A1.8 mm0.0709 in
Mark B1.85 mm0.0728 in
Mark C1.9 mm0.0748 in
Mark D1.95 mm0.0768 in
Mark E2 mm0.787 in
Mark F2.05 mm0.0807 in
Mark G2.08 mm0.0819 in
Mark H2.11 mm0.0831 in
Mark J2.14 mm0.0843 in
Mark K2.17 mm0.0854 in
Mark L2.2 mm0.0866 in
Mark M2.23 mm0.0878 in
Mark N2.26 mm0.089 in
Mark P2.29 mm0.0902 in
Mark Q2.32 mm0.0913 in
Mark R2.35 mm0.0925 in
Mark S2.4 mm0.0945 in
Mark T2.45 mm0.0965 in
Mark U2.5 mm0.0984 in
Mark V2.55 mm0.1004 in
Mark W2.6 mm0.1024 in
Mark X2.65 mm0.1043 in
Mark Y2.7 mm0.1063 in
Application
Specification
MetricEnglish
Mark 11.70 mm0.0669 in
Mark 21.75 mm0.0689 in
Mark 31.80 mm0.0709 in
Mark 41.85 mm0.0728 in
Mark 51.90 mm0.0748 in
Mark 61.93 mm0.0760 in
Mark 71.96 mm0.0772 in
Mark A1.99 mm0.0783 in
Mark B2.02 mm0.0795
Mark C2.05 mm0.0807 in
Mark D2.08 mm0.0819 in
Mark E2.11 mm0.0831 in
Mark F2.14 mm0.0843 in

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Flange Thickness
Accumulator Spring
TRANSMISSION GEAR RATIO
Transmission Gear Ratio
Mark G2.17 mm0.0854 in
Mark H2.20 mm0.0866 in
Mark K2.25 mm0.0886 in
Mark L2.30 mm0.0906 in
Mark M2.35 mm0.0925 in
Mark N2.40 mm0.0945 in
Mark P2.45 mm0.0965 in
Mark Q2.50 mm0.0984 in
Mark R2.55 mm0.1004 in
Mark S2.60 mm0.1024 in
Mark U2.65 mm0.1043 in
Mark W2.70 mm0.1063 in
MarkPiston StrokeThickness
MetricEnglishMetricEnglish
00.738-0.949 mm0.02905-0.03736 in3.0 mm0.118 in
10.950-1.149 mm0.03740-0.04524 in3.2 mm0.126 in
21.150-1.349 mm0.04528-0.05311 in3.4 mm0.134 in
31.350-1.549 mm0.05315-0.06098 in3.6 mm0.142 in
01.550-1.702 mm0.06102-0.06701 in3.8 mm0.150 in
Spring
Free length Outer Diameter
ColorMetricEnglish
O/D and 2nd brake47.13 mm/16.0 mm1.8555 in/0.630 inPink
Forward Clutch57.90 mm/17.2 mm2.2795 in/0.677 in-
Direct Clutch57.20 mm/17.5 mm2.2520 in/0.689 inGreen
GearRatio
First2.875
Second1.568
Third1.000
Fourth0.697
Reverse2.300
Counter1.019
Differential 1.4L/1.5L/1.2L SOHC3.750
Differential 1.4L DOHC4.052

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.

FLUID CAPACITY SPECIFICATIONS
Fluid Capacity Specifications
SHIFT SPEED
Fig. 1: Economic Mode (1.4/1.5L SOHC)

Courtesy of GENERAL MOTORS CORP.
Application
Specification
MetricEnglish
Transmission Fluid-Drain and Refill2.1L2.2 qt
Transmission Fluid-Dry Fill - 1.4L/1.5L/1.2L SOHC5.6L5.9 qt
Transmission Fluid-Dry Fill - 1.4L DOHC5.8L6.2 qt

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 5 © 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Economic Mode (1.2L SOHC)
Courtesy of GENERAL MOTORS CORP.
Fig. 3: Economic Mode (1.4L DOHC)

Courtesy of GENERAL MOTORS CORP.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisi n (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 6 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Power Mode (1.4/1.5L SOHC)
Courtesy of GENERAL MOTORS CORP.
Fig. 5: Power Mode (1.2L SOHC)

Courtesy of GENERAL MOTORS CORP.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisi n (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 7 © 2005 Mitchell Repair Information Company, LLC.

Fig. 6: Power Mode (1.4L DOHC)
Courtesy of GENERAL MOTORS CORP.
Fig. 7: Up
-Slope 1 Mode (1.4/1.5L SOHC)
Courtesy of GENERAL MOTORS CORP.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisi n (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 8 © 2005 Mitchell Repair Information Company, LLC.

Fig. 8: Up-Slope 1 Mode (1.2L SOHC)
Courtesy of GENERAL MOTORS CORP.
Fig. 9: Up
-Slope 1 Mode (1.4L DOHC)
Courtesy of GENERAL MOTORS CORP.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisi n (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 9 © 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Up-Slope 2 Mode (1.4/1.5L SOHC)
Courtesy of GENERAL MOTORS CORP.
Fig. 11: Up
-Slope 2 Mode (1.2L SOHC)
Courtesy of GENERAL MOTORS CORP.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisi n (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 10 © 2005 Mitchell Repair Information Company, LLC.

Fig. 12: Up-Slope 2 Mode (1.4L DOHC)
Courtesy of GENERAL MOTORS CORP.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 11 © 2005 Mitchell Repair Information Company, LLC.