CHEVROLET AVEO 2002 Service Repair Manual

Fig. 269: Forward Clutch Hub & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
80. Install the forward clutch hub to the transaxle case.

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Fig. 270: Thrust Bearing Race & Forward Clutch Hub
Courtesy of GENERAL MOTORS CORP.
81. Coat the thrust bearing race with petroleum jelly and install the race onto the forward clutch hub.
Specification:
The race inner diameter is 19.3 mm (0.760 in).
The race outer diameter is 30.6 mm (1.205 in).

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Fig. 271: Thrust Needle Roller Bearing, Race & Forward/Reverse Clutch Assembly
Courtesy of GENERAL MOTORS CORP.
82. Install the thrust bearing race and thrust needle roller bearing to the forward and reverse clutch assembly.
Specification:
The race inner diameter is 18.1 mm (0.713 in).
The race outer diameter is 28.2 mm (1.110 in).
The bearing inner diameter is 18.1 mm (0.713 in).
The bearing outer diameter is 29.6 mm (1.165 in).

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Fig. 272: Forward/Reverse Clutch Assembly & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
83. Install the forward and reverse clutch assembl
y to the transaxle case.

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Fig. 273: Sliding Surface Of Disc
Courtesy of GENERAL MOTORS CORP.
84. If the sliding surface of the disc, the plate and the flange of 2nd coast and O/D brake are worn or burnt,
replace the components.
IMPORTANT:If the lining of the disc is peeling off or discolored, or even if the part
of the printed mark is defaced, replace all discs.
Before assembling new discs, soak the discs in ATF for at least 15
minutes.

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Fig. 274: Installing Snap Ring To Transaxle Case Using A Screwdriver
Courtesy of GENERAL MOTORS CORP.
85. Usin
g a screwdriver, install the snap ring to the transaxle case.
IMPORTANT: Install the snap ring in the groove of the transaxle case correctly.

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Fig. 275: O/D Brake Flange, Discs & Plates
Courtesy of GENERAL MOTORS CORP.
86. Install the flange, 2 discs and 2 plates to the transaxle case in the following order: 3-2-3-2-1, where (3)
=Plate, (2)=-Disc, and (1)=Flange.
87. Clean the connected part the transaxle case and the transaxle rear cover.

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Fig. 276: Measuring The Distance Between 2nd Coast & O/D Brake Flange Using Vernier Calipers
Courtesy of GENERAL MOTORS CORP.
88. Place a straight edge on the transaxle case and measure the distance between the 2nd coast and the O/D
brake flange and the straight edge using vernier calipers (a).

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Fig. 277: Measuring The Distance Between Transaxle Rear Cover & Straight Edge Using Vernier
Calipers
Courtesy of GENERAL MOTORS CORP.
89. Place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover
and the straight edge using vernier calipers (a).
90. Calculate the piston stroke value using the following formula. Select and install a flange which satisfies
the piston stroke value.

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Fig. 278: Apply Gaskets & Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
91. Install 4 new appl
y gaskets to the transaxle rear cover.

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