CHEVROLET AVEO 2002 Service Repair Manual

Fig. 22: Case And Associated Parts (2 of 2)
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 22
CalloutComponent Name
1Oil Seal
2Transaxle Housing
3Oil Reservoir Plate
4Transaxle Oil Apply Pipe
5Spring
6Check Valve Pipe Clamp
7Apply Gasket
8Brake Drum Gasket
9Differential Gear Oil Apply Pipe

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 22 © 2005 Mitchell Repair Information Company, LLC.

10O-Ring
11Transaxle Wire
12Torsion Spring
13Transaxle Oil Apply Pipe Clamp
14Parking Lock Pawl
15Manual Valve Lever
16Spacer
17Oil Seal
18Park/Neutral Position Switch
19Lock Washer
20Control Lever
21Washer
22Spring
23O-Ring
24Overdrive Brake Accumulator Piston
25O-Ring
26Spring
27O-Ring
28Forward Clutch Accumulator Piston
29O-Ring
30O-Ring
31Direct Clutch Accumulator Piston
32O-Ring
33Spring
34Manual Detent Spring
35Pin
36Parking Lock Rod
37Parking Lock Pawl Shaft
38Manual Valve Lever Shaft
39Parking Lock Pawl Bracket
40Oil Pan
41Gasket
42Magnet
43Oil Strainer
44Gasket
45Valve Body

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 23 © 2005 Mitchell Repair Information Company, LLC.

Fig. 23: Internal Components View
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 23
CalloutComponent Name
1Planetary Ring Gear
2O-Ring
31st and Reverse Brake Piston
4O-Ring
51st and Reverse Brake Piston Return Spring
6Plate
7Disc
8Flange

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 24 © 2005 Mitchell Repair Information Company, LLC.

9Snap Ring
10Planetary Gear
11Thrust Washer
12No. 2 One-Way Clutch
13Anti-Rattle Clip
14Flange
15Disc
16Plate
172nd Brake Piston Return Spring
18O-Ring
192nd Brake Piston
20O-Ring
212nd Brake Clutch Cylinder
22Snap Ring
23Thrust Bearing Race
24Front Planetary Sun Gear
25Thrust Bearing Race
26One-Way Clutch Assembly
27Thrust Washer
28Rear Planetary Sun Gear
29Snap Ring
30Flange
31Disc
32Plate
33Thrust Bearing Race
34Thrust Needle Roller Bearing
35Forward Clutch Hub
36Thrust Bearing Race
37Thrust Needle Roller Bearing
38Thrust Bearing Race
39Forward and Reverse Clutch Assembly
40Thrust Needle Roller Bearing
41Snap Ring
42O/D Brake Return Spring
43O/D Brake Piston
44O-Ring
45Seal Ring
46Transaxle Rear Cover
47Apply Gasket
48O-Ring
49Screw Plug

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 25 © 2005 Mitchell Repair Information Company, LLC.

Fig. 24: Differential And Oil Pump Component View
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 24
CalloutComponent Name
1Side Bearing Outer Race
2Shim
3Outer Tapered Roller Bearing Race
4Counter Driven Gear
5Oil Seal
6Transaxle Case Plate
7Apply Gasket
8Counter Driven Gear
9Direct Clutch Hub
10Thrust Bearing Race
11Direct Clutch Assembly
12Thrust Needle Roller Bearing
13Differential Case
14Oil Pump

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 26 © 2005 Mitchell Repair Information Company, LLC.

Fig. 25: Bearing And Race Installation And Direction Component View
Courtesy of GENERAL MOTORS CORP.
Disassembled Views
Mark
Front Race DiameterThrust Bearing DiameterRear Race Diameter
InsideOutsideInsideOutsideInsideOutside
1--32.5 mm
(1.280 in)48.5 mm
(1.909 in)--
2--17.8 mm
(0.701 in)30.2 mm
(1.189 in)20.5 mm
(0.807 in)32.6 mm
(1.283 in)
319.3 mm
(0.760 in)29.0 mm
(1.142 in)----
4--42.5 mm 57.5 mm --

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 27 © 2005 Mitchell Repair Information Company, LLC.

SHIFT SELECT CONTROL
Fig. 26: Shift Select Control

Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 26
(1.673 in)(2.264 in)
534.95 mm
(1.3670 in)45.50 mm
(1.7913 in)33.3 mm
(1.311 in)46.5 mm
(1.831 in)--
619.3 mm
(0.760 in)30.6 mm
(1.205 in)18.1 mm
(0.713 in)29.6 mm
(1.165 in)18.1 mm
(0.713 in)28.2 mm
(1.110 in)
7--43.2 mm
(1.701 in)62.0 mm
(2.441 in)--
CalloutComponent Name
1Nut

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 28 © 2005 Mitchell Repair Information Company, LLC.

CONNECTOR END VIEWS
Automatic Transmission Connector
2Select Control Lever Assembly
3Bolt
4Cable Fastener
5Clamp
6E-Ring
7Bolt
8Select Control Cable
9Shift Program Switch
10Shift Indicator Lamp
Connector Part InformationYazaki 7283-1407-40
10-Way (GY)
PinWire ColorCircuit No.Function
1PU898Transmission Fluid Temperature Sensor
Signal
2PK1224Timing Valve Control
3RD1226Pressure Control Solenoid Control
4D-BU1225Torque Converter Clutch Solenoid Control
5L-GN1222Shift Solenoid 1 Valve Control
6OG/BK586Transmission Fluid Temperature Sensor Low
Reference
7--Not Used
8YE/BK1227Low Reference
9--Not Used

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 29 © 2005 Mitchell Repair Information Company, LLC.

Input Shaft Speed (ISS) Sensor
Park/Neutral Position (PNP) Switch (1.2L)
10YE/BK1223Shift Solenoid 2 Valve Control
Connector Part InformationYazaki 7283-8125-90
2-Way F (BU)
PinWire ColorCircuit No.Function
1YE/BK1297Input Shaft Speed (ISS) Sensor Low Signal
2D-BU/WH1296Input Shaft Speed (ISS) Sensor High Signal
Connector Part InformationYazaki 7283-1909-40
9-Way F (GY)
PinWire ColorCircuit No.Function
1BN323Park/Neutral Position (PNP) Switch Signal
2GY2380Park/Neutral Position (PNP) Switch Low

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 30 © 2005 Mitchell Repair Information Company, LLC.

Park/Neutral Position (PNP) Switch (1.4L, 1.5L, 1.6L)
Gear Signal
3WH2377Park/Neutral Position (PNP) Switch Drive
Signal
4BK51Ground
5YE2381Park/Neutral Position (PNP) Switch Neutral
Signal
6PK2384Park/Neutral Position (PNP) Switch 2nd
Gear Signal
7PK839Ignition 1 Voltage
8D-GN/WH2383Park/Neutral Position (PNP) Switch Reverse
Signal
9D-GN/YE2382Park/Neutral Position (PNP) Switch Park
Signal
Connector Part InformationYazaki 7283-1909-40
9-Way F (GY)
PinWire ColorCircuit No.Function
1D-GN/YE2382Park/Neutral Position (PNP) Switch Park
Signal
2D-GN/WH2383Park/Neutral Position (PNP) Switch Reverse
Signal
3PK839Ignition 1 Voltage
4PK2384Park/Neutral Position (PNP) Switch 2nd
Gear Signal
5YE2381Park/Neutral Position (PNP) Switch Neutral
Signal
6BK51Ground
Park/Neutral Position (PNP) Switch Drive

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 31 © 2005 Mitchell Repair Information Company, LLC.