CHEVROLET AVEO 2002 Service Repair Manual

Fig. 200: Applying Compressed Air To Transaxle Rear Cover To Remove O/D Brake Piston
Courtesy of GENERAL MOTORS CORP.
93. Appl
y 392 kPa (57 psi) of compressed air to the transaxle rear cover to remove the O/D brake piston.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice .
IMPORTANT:
Air pressure may cause the pistons to jump out. When removing the
piston, hold it in place with your hand using a waste cloth.
Take care not to splash ATF when air-blowing.

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Fig. 201: O-Rings & O/D Brake Piston
Courtesy of GENERAL MOTORS CORP.
94. Remove the 2 O-rings (1) from the O/D brake piston.

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Fig. 202: Seal Rings & Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
95. Remove the 2 seal rin
gs from the transaxle rear cover.
IMPORTANT: Do not expand the seal ring excessively.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 203: Screw Plugs, 4 O-Rings & Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
96. Remove the 4 screw plugs and 4 O-rings from the transaxle rear cover.
TRANSMISSION ASSEMBLE
Tools Required
DT 46451 (DW240-020) Brake Clutch Spring Compressor. See Special Tools.
DT 46454 (DW240-050) Overdrive Brake Adapter. See Special Tools.
DT 46455 (DW240-060-01) Brake Spring Compressor Bolt/Nut. See Special Tools.
DT 46456 (DW240-060-02) Brake Spring Compressor Plate. See Special Tools.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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DT 46457 DW240-070) 1st/Reverse Brake Adapter. See Special Tools.
DT 46458 (DW240-080) 2nd Brake Adapter. See Special Tools.
DT 46460 (DW240-100) Counter Drive Gear Installation Adapter. See Special Tools.
DT 46461 (DW240-130) Differential Preload Adapter. See Special Tools.
DT 46462 (DW240-140) Transaxle Housing Side Bearing Outer Race Adapter. See Special Tools.
DT 46464 (DW240-160) Transaxle Case Outer Tapered Roller Bearing Race Adapter. See Special Tools.
DT 46465 (DW240-170) Adapter Handle. See Special Tools.
DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer. See Special Tools.
DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket. See Special Tools.
DT 47521 (DW260-031-02) Transaxle Case Oil Seal Installer. See Special Tools.
Assembly Procedure

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 204: Screw Plugs, 4 O-Rings & Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
1. Install 4 new O-rings to the 4 screw plugs.
2. Install the 4 screw plugs with the O-rings to the transaxle rear cover.
Tighten: Ti
ghten the screw plugs to 7.4 N.m (65 lb in).
NOTE: Refer to Fastener Notice .

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Fig. 205: Seal Rings & Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
3. Install the 2 seal rin
gs to the transaxle rear cover.

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Fig. 206: Measuring Free Length Of O/D Brake Piston Return Spring Using The Vernier Calipers
Courtesy of GENERAL MOTORS CORP.
4. Using the vernier calipers, measure the free length of the overdrive (O/D) brake piston return spring
together with the spring seat.
Specification: The standard free len
gth is 18.99 mm (0.7476 in).

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Fig. 207: O-Rings & O/D Brake Piston
Courtesy of GENERAL MOTORS CORP.
5. Coat 2 new O-rings (1) with automatic transaxle fluid (ATF). Install the O-rings to the O/D brake piston.

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Fig. 208: O/D Brake Piston & ATF
Courtesy of GENERAL MOTORS CORP.
6. Coat the O/D brake piston with ATF. Install the piston to the transaxle rear cover.
IMPORTANT: Do not damage the O-rings of the O/D brake piston.

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