CHEVROLET AVEO 2002 Service Repair Manual

Fig. 279: Thrust Needle Roller Bearing & Forward/Reverse Clutch Assembly
Courtesy of GENERAL MOTORS CORP.
92. Coat the thrust needle roller bearing with petroleum jelly and install the bearing onto the forward and
reverse clutch assembly.
Specification:
The bearing inner diameter is 43.2 mm (1.701 in).
The bearing outer diameter is 62.0 mm (2.441 in).
93. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle rear cover or
transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:26 PMPage 292 © 2005 Mitchell Repair Information Company, LLC.

Fig. 280: Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
94. Apply a formed in place gasket (FIPG) to the transaxle rear cover.
Specification: The FIPG three bond 1281, or equivalent, seal bend width is 1.2 mm (0.047 in).

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:26 PMPage 293 © 2005 Mitchell Repair Information Company, LLC.

Fig. 281: Transaxle Rear Cover, Transaxle Case & Bolts
Courtesy of GENERAL MOTORS CORP.
95. Install the transaxle rear cover to the transaxle case with 9 bolts.
Tighten: Ti
ghten the bolts to 25 N.m (18 lb ft).

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:26 PMPage 294 © 2005 Mitchell Repair Information Company, LLC.

Fig. 282: Counter Driven Gear Assembly & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
96. Install the counter driven
gear assembly to the transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:26 PMPage 295 © 2005 Mitchell Repair Information Company, LLC.

Fig. 283: Differential Gear Assembly & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
97. Install the differential
gear assembly to the transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:26 PMPage 296 © 2005 Mitchell Repair Information Company, LLC.

Fig. 284: Direct Clutch Hub & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
98. Install the direct clutch hub to the transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:26 PMPage 297 © 2005 Mitchell Repair Information Company, LLC.

Fig. 285: Thrust Bearing Race, Thrust Needle Roller Bearing & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
99. Install the thrust bearing race and the thrust needle roller bearing to the transaxle case.
Specification:
The race inner diameter is 20.5 mm (0.807 in).
The race outer diameter is 32.6 mm (1.283 in).
The bearing inner diameter is 17.8 mm (0.701 in).
The bearing outer diameter is 30.2 mm (1.189 in).

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:26 PMPage 298 © 2005 Mitchell Repair Information Company, LLC.

Fig. 286: Direct Clutch Assembly & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
100. Install the clutch assembl
y to the transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:26 PMPage 299 © 2005 Mitchell Repair Information Company, LLC.

Fig. 287: Apply Gasket
Courtesy of GENERAL MOTORS CORP.
101. Install the new appl
y gasket.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:26 PMPage 300 © 2005 Mitchell Repair Information Company, LLC.

Fig. 288: Oil Pump & Input Shaft
Courtesy of GENERAL MOTORS CORP.
102. Install the thrust needle roller bearing to the transaxle case.
103. Place the oil pump through the input shaft, and align the bolt holes of the oil pump with the transaxle
case.
IMPORTANT: Verify the direction of the bearing.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:26 PMPage 301 © 2005 Mitchell Repair Information Company, LLC.