lock CHEVROLET AVEO 2002 Service Repair Manual

A. Front Planetary Gear
B. Rear Planetary Gear
Reverse Gear
1. The input shaft rotates clockwise.
The reverse clutch (C3) operates. Connect the input shaft to the rear planetary sun gear.
2. The planetary long pinion rotates itself counterclockwise.
3. The 1st and reverse brake (3) operates. Lock rotates the planetary carrier.
4. The ring gear rotates counterclockwise.
5. The counter drive gear rotates counterclockwise for the ring gear and one.
6. The counter driven gear rotates clockwise.
7. The differential gear drive pinion rotates clockwise for the counter driven gear and one.
8. The differential gear rotates counterclockwise.
Engine Brake
The driving force is connected to the input shaft directory without the 1-way clutch. Therefore the engine brake
operates.
TRANSMISSION GENERAL DESCRIPTION
The new automatic transmission AISIN (81-40LE) is an electronically controlled 4-speed automatic
transmission with lock-up mechanism.
The transmission is mainly composed of the torque converter with lock up clutch, newly developed 4-speed
planetary gear unit, the hydraulic control system and the electric control system.
Hydraulic Control System
Based on the hydraulic pressure created by the oil pump, the TCM sends signals to the solenoid and the
hydraulic control system governs the hydraulic pressure acting on the torque converter, planetary gear, clutches,
and brakes in accordance with the vehicle driving conditions.
Function of Components
NOTE: Lack of basic knowledge of this powertrain when performing diagnostic
procedures could result in incorrect diagnostic performance or damage to
powertrain components. Do not attempt to diagnose a powertrain problem
without this basic knowledge.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 448: Function Of Components
Courtesy of GENERAL MOTORS CORP.
Function of Components
ComponentFunction
7Forward ClutchConnects the input shaft and front sun gear.
3Direct ClutchConnects the input shaft and planetary carrier.
5Reverse ClutchConnects the input shaft and rear sun gear.
6O/D and 2nd BrakePrevents rear planetary sun gear from turning
either clockwise or counterclockwise.
42nd Brake
Prevents outer race of 8 from turning either
clockwise or counterclockwise, thus
preventing the rear sun gear turning

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Operations of Clutches and Brakes
Fig. 449: Operations Of Clutches And Brakes
Courtesy of GENERAL MOTORS CORP.
Operations of Clutches and Brakes
counterclockwise.
21st and Reverse BrakePrevents the planetary carrier from turning
either clockwise or counterclockwise.
8No. 1 One-Way ClutchWhen 4 is operating, this clutch prevents rear
sun gear from turning counterclockwise.
1No. 2 One-Way ClutchPrevents the planetary carrier from turning
counterclockwise.
Planetary Gear
These gears change the route through which
driving force is transmitted, in accordance
with the operation of each clutch and brake, in
order to increase or reduce the input and
output speed.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Transmission Range Reference
Clutch and BrakeOperation
C1Forward Clutch
Connects the intermediate shaft and the front
sun gear.
C2Direct ClutchConnects the input shaft and the planetary
carrier.
C3Reverse ClutchConnects the intermediate shaft and the rear
sun gear.
B1O/D and 2nd BrakeLock rear sun gear
B22nd BrakeLock rear sun gear
B31st and Reverse BrakeLock planetary carrier
F11-Way Clutch No. 1Lock counterclockwise rotation of the rear sun
gear, when B2 operations
F21-Way Clutch No. 2Lock counterclockwise rotation of the
planetary carrier
PositionSolenoidClutchBrakeOne-Way
Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
PONONOFFOFFOFFOFFOFFOFFOFFOFFOFF
R
V less
than 9
km/h (5
mph)
ONONOFFOFFOFFONOFFOFFONOFFOFF
V
greater
than or
equal to
9 km/h
(5 mph)
ONONONOFFOFFOFFOFFOFFOFFOFFOFF
NONONOFFOFFOFFOFFOFFOFFOFFOFFOFF
D
1stONONOFFONOFFOFFOFFOFFOFFOFFON
2ndONOFFOFFONOFFOFFOFFONOFFONOFF
3rdOFFOFFOFFONONOFFOFFONOFFOFFOFF
3-4OFFONON-
OFFON-
OFFONOFFOFF-
ONONOFFOFFOFF
4thOFFONOFFOFFONOFFONONOFFOFFOFF
2
1stONONOFFONOFFOFFOFFOFFOFFOFFON
2ndONOFFOFFONOFFOFFONONOFFONOFF
3rdOFFOFFOFFONONOFFOFFONOFFOFFOFF
11stONONOFFONOFFOFFOFFOFFONOFFON
2ndONOFFOFFONOFFOFFONONOFFONOFF

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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ELECTRONIC COMPONENT DESCRIPTION
Transmission Control Module (TCM)
The transmission control module (TCM) primarily controls shift points and lockup engagement. It is located on
the driver side under the instrument panel.
The transmission is controlled by an electronic shift system. The TCM processes input signals. From the
information received, the TCM controls the transmission hydraulic system.
The electronic shift system consists of the following components.
TCM
Shift solenoids (SS1 and SS2)
Pressure control solenoid (PCS)
Lockup solenoid
Input shaft speed (ISS) sensor
Output shaft speed (OSS) sensor
Transmission fluid temperature (TFT) sensor
Park/neutral position (PNP) switch
Park/Neutral Position (PNP) Switch
The PNP switch transmits the information which range includes the shift lever of the automatic transmission
(A/T) to the starter and TCM.
It is possible for the PNP switch to start an engine in only park (P) and neutral (N) prevention of reckless
driving
The PNP switch makes the backup lamp turn on when reversing.
It is used for PNP switch to shift control.
The PNP switch transmits the information by combination of starter and reverse circuit to the vehicle side
directl
y without TCM.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:34 PMPage 470 © 2005 Mitchell Repair Information Company, LLC.

Fig. 453: Timing Solenoid
Courtesy of GENERAL MOTORS CORP.
Lock-Up Solenoid
The lock-up solenoid (1) is installed in the valve body. It receives control signal from TCM.
The lock-up solenoid operates the lock-up valve inside the valve body and controls the torque converter lockup
function.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 454: Lock-Up Solenoid
Courtesy of GENERAL MOTORS CORP.
Pressure Control Solenoid (PCS)
The PCS (1) is located inside the valve body and regulates the transmission's fluid pressure system. It is
internally grounded in the TCM and operates when it is supplied with battery voltage from the TCM, through
the PCS and back to the TCM.
The battery voltage is controlled by a varying current from the TCM.
The strength of the current is a function of the throttle position.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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2005 ACCESSORIES & EQUIPMENT
Instrument Panel, Gages, & Console - Aveo
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
BULB USAGE SPECIFICATIONS
Bulb Usage Specifications
Application
Specification
MetricEnglish
Chime Module Screws3.5 N.m31 lb in
Clock Screws2.5 N.m22 lb in
Cupholder Screws2.5 N.m22 lb in
Floor Console Screws4 N.m35 lb in
HVAC Controls Screws4 N.m35 lb in
Instrument Cluster Screws4 N.m35 lb in
Instrument Cluster Trim Panel Screws4 N.m35 lb in
Instrument Panel Bolts Behind the HVAC Controls4 N.m35 lb in
Instrument Panel End Bolts4 N.m35 lb in
Instrument Panel Bolts20 N.m15 lb ft
Indicator LampColorBulb
ABS WiringAmber14 V 1.4 W
Air Bag WarningRed14 V 1.4 W
Battery Charge IndicatorRed14 V 1.4 W
Check EngineAmber14 V 1.4 W
Door Open WarningRed14 V 1.4 W
Engine OverheatRed14 V 1.4 W
Fasten Seat Belt WarningRed14 V 1.4 W
High Beam IndicatorBlue14 V 1.4 W
Low Fuel Level WarningAmber14 V 1.4 W
Oil Pressure WarningRed14 V 1.4 W
Parking Brake Indicator and Brake
Fluid WarningRed14 V 1.4 W
Service Engine Soon WarningAmber14 V 1.4 W
Transaxle Power Mode IndicatorAmber14 V 1.4 W
Turn Signal IndictorsGreen14 V 1.4 W

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Friday, July 31, 2009 1:07:07 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.

Fig. 7: I/P Components Component Views
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 9
CalloutComponent Name
1Multifunction Alarm Module
2Ignition Key Alarm Switch
3Defogger Switch
4Clock/Tele Tail
5Cluster
6Radio
7Tweeter Right/Left Similar
8Cigar Lighter
9Wiper Switch
10Blower Switch
11Horn Switch

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 8 © 2005 Mitchell Repair Information Company, LLC.

INSTRUMENT PANEL, GAGES, AND CONSOLE CONNECTOR END VIEWS
Clock
12Headlamp Switch
Connector Part InformationKM 01-20DS-HU
20-Way M (BK)
PinWire ColorCircuit No.Function
1WH629Daytime Running Lamp (DRL) On Indicator
Control (w/Tach)
2L-BU122Rear Fog Lamp Supply Voltage (Rear Fog
Lamps)
3D-GN/WH157Courtesy Lamp Control
4D-GN867ABS Warning Indicator Control (w/ABS)
5OG540Battery Positive Voltage
6BK450Ground
7D-GN/YE358Air Bag Indicator Control (w/Tach)
8L-BU318Front Fog Lamp Supply Voltage (w/Front
Fog Lamps)
9BK/WH238Seat Belt Switch - Driver (w/Tach)
10YE749Security Indicator Control
11BN/BK419Malfunction Indicator Lamp (MIL) Control
(w/Tach)
12--Not Used
13D-GN31Oil Pressure Indicator Control (w/Tach)
14YE1481Hold Mode Indicator Control
15YE43Accessory Voltage
16BN/WH309Right Park Lamp Supply Voltage

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 9 © 2005 Mitchell Repair Information Company, LLC.