CHEVROLET AVEO 2002 Service Repair Manual

Fig. 229: O-Rings & 1st & Reverse Brake Piston
Courtesy of GENERAL MOTORS CORP.
33. Coat 2 new O-rin
gs (1) with ATF, install the O-rings to the 1st and reverse piston.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:24 PMPage 242 © 2005 Mitchell Repair Information Company, LLC.

Fig. 230: 1st & Reverse Brake Piston
Courtesy of GENERAL MOTORS CORP.
34. Install the 1st and reverse brake piston to the transaxle case.
IMPORTANT: Do not damage the O-rings of the 1st and reverse brake piston.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:24 PMPage 243 © 2005 Mitchell Repair Information Company, LLC.

Fig. 231: Return Spring & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
35. Install the return spring to the transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:24 PMPage 244 © 2005 Mitchell Repair Information Company, LLC.

Fig. 232: Plates, Discs & Flange
Courtesy of GENERAL MOTORS CORP.
36. Install the 4 plates, the 4 discs and the flange in order: 2-1-2-1-2-1-2-1-3, where (2)=Plate, (1)=Disc, and
(3)=Flan
ge

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:24 PMPage 245 © 2005 Mitchell Repair Information Company, LLC.

Fig. 233: DT 46455, DT 46457, Snap Ring Of 1st & Reverse Brake
Courtesy of GENERAL MOTORS CORP.
37. Usin
g DT 46457 (2) and DT 46455 (1), install the snap ring. See Special Tools.
IMPORTANT: Verify that the snap ring is installed correctly in the groove of the
transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:24 PMPage 246 © 2005 Mitchell Repair Information Company, LLC.

Fig. 234: Measuring The 1st & Reverse Brake Piston Stroke Using A Dial Indicator
Courtesy of GENERAL MOTORS CORP.
38. Using a dial indicator, measure the 1st and reverse brake piston stroke while applying and releasing 392-
785 kPa (57-114 psi) of compressed air.
IMPORTANT: If the piston stroke is non-standard, inspect the discs, the plates and the
flange. The piston stroke is 0.6-1.3 mm (0.024-0.051 in).

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:24 PMPage 247 © 2005 Mitchell Repair Information Company, LLC.

Fig. 235: DT 46460, DT 46455 & DT 46456
Courtesy of GENERAL MOTORS CORP.
39. Usin
g DT 46460 (3), DT 46455 (2) and DT 46456(1), install the counter drive gear. See Special Tools.
IMPORTANT: Do not apply excessive force to the transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:24 PMPage 248 © 2005 Mitchell Repair Information Company, LLC.

Fig. 236: Transaxle Housing & Counter Driven Gear
Courtesy of GENERAL MOTORS CORP.
40. Coat a new oil seal with ATF.
41. Install the oil seal to the transaxle case.
Specification: The oil seal depth is 0.75-1.25 mm (0.030-0.049 in).

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:25 PMPage 249 © 2005 Mitchell Repair Information Company, LLC.

Fig. 237: Parking Lock Rod & Manual Valve Lever
Courtesy of GENERAL MOTORS CORP.
42. Install the parkin
g lock rod to the manual valve lever.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:25 PMPage 250 © 2005 Mitchell Repair Information Company, LLC.

Fig. 238: Spacer & Manual Valve Lever
Courtesy of GENERAL MOTORS CORP.
43. Install a new spacer to the manual valve lever.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:25 PMPage 251 © 2005 Mitchell Repair Information Company, LLC.