CHEVROLET AVEO 2002 Service Repair Manual

Fig. 219: Differential Gear & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
20. Install the differential
gear to the transaxle case.

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Fig. 220: Installing Transaxle Housing
Courtesy of GENERAL MOTORS CORP.
21. Install the transaxle housing and hand tighten the 16 bolts of the transaxle housing.
22. Tighten 8 or 9 bolts of the transaxle housing completely.
Tighten: Ti
ghten the bolts to 29 N.m (22 lb ft).

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Fig. 221: Turning The Differential Gear Assembly
Courtesy of GENERAL MOTORS CORP.
23. Using DT 46461 , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to
settle. See Special Tools
.

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Fig. 222: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
Courtesy of GENERAL MOTORS CORP.
24. Using DT 46461 and a small torque wrench, measure the preload of the differential gear. See Special
Tools.
IMPORTANT: Note the measured value.

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Fig. 223: Transaxle Housing & Counter Driven Gear
Courtesy of GENERAL MOTORS CORP.
25. Remove the transaxle housin
g and install the counter driven gear.

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Fig. 224: Installing Transaxle Housing
Courtesy of GENERAL MOTORS CORP.
26. Install the transaxle housing and hand tighten the 16 bolts of the transaxle housing.
27. Tighten 8 or 9 bolts of the transaxle housing completely.
Tighten: Ti
ghten the bolts to 29 N.m (21 lb ft).

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Fig. 225: Turning The Differential Gear Assembly
Courtesy of GENERAL MOTORS CORP.
28. Using DT 46461 , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to
settle. See Special Tools
.

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Fig. 226: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
Courtesy of GENERAL MOTORS CORP.
29. Using DT 46461 and a small torque wrench, measure the preload of the differential gear. See Special
Tools. From this value deduct the value measured previously. This new value is the preload of the
counter driven gear.
Specification:
The preload for a new bearing is 0.33-0.76 N.m (3.21-6.77 lb in).
The preload for a used bearing is 0.17-0.38 N.m (1.48-3.39 lb in).
30. If the preload of the counter driven gear does not satisfy the specification, select the adjuster shim from
the table below and re-measure the value. Until the value is within the specification, repeat the procedure.
IMPORTANT: When the preload is larger than the specification, select a thinner adjuster
shim. When the preload is smaller than specification, select a thicker
adjuster shim.

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Fig. 227: Measuring The Free Length Of 1st & Reverse Brake Piston Return Spring Using The
Vernier Calipers
Courtesy of GENERAL MOTORS CORP.
31. Using the vernier calipers, measure the free length of the 1st and reverse brake piston return spring
together with the spring seat.
Specification: The standard free len
gth is 18.053 mm (0.71075 in).

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Fig. 228: Sliding Surface Of Disc
Courtesy of GENERAL MOTORS CORP.
32. Inspect the sliding surface of the disc, the plate and the flange of the 1st and reverse brake for wear or
burn. Replace the parts, if necessary.
IMPORTANT:If the lining of the disc is peeling off or discolored, or even if a part
of the groove is defaced, replace all discs.
Before assembling the new discs, soak the discs in ATF for at least
15 minutes.

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