CHEVROLET AVEO 2002 Service Repair Manual

1. Using a suitable puller, remove the tapered roller bearing from the transaxle case side.
Fig. 388: Counter Driven Gear

Courtesy of GENERAL MOTORS CORP.
2. Usin
g a press, remove the counter driven gear.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 389: Removing Outer & Tapered Roller Bearing Race Using A Puller
Courtesy of GENERAL MOTORS CORP.
3. Using a suitable puller, remove the tapered roller bearing.
4. Using a suitable puller, remove the outer tapered roller bearing race and shim from the transaxle case.
5. Using a suitable puller, remove the outer tapered roller bearing race from the transaxle housing.
COUNTER DRIVE GEAR ASSEMBLE
Tools Required
DT 46464 (DW240-160) Transaxle Case Outer Tapered Roller Bearing Race Adapter. See Special Tools.
DT 46465 (DW240-170) Adapter Handle. See Special Tools.

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Fig. 390: Oil Seal & Transaxle Housing
Courtesy of GENERAL MOTORS CORP.
1. Install a new outer tapered roller bearin
g race into the transaxle housing.
IMPORTANT: Press-fit the outer tapered roller bearing race until it contacts the
transaxle housing.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 391: Pressing In A New Outer Tapered Roller Bearing Race Using DT 46464 & DT 46465
Courtesy of GENERAL MOTORS CORP.
2. Install the shim to the transaxle case.
3. Using the DT 46464 (2) and the DT 46465 (1), press in a new outer tapered roller bearing race into the
transaxle case. See Special Tools
.
IMPORTANT: Press-fit the shim until it contacts the transaxle case.
IMPORTANT: Install a shim of the same thickness as the one removed.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 392: Counter Driven Gear
Courtesy of GENERAL MOTORS CORP.
4. Usin
g a press, install the counter driven gear.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 393: Tapered Roller Bearing & Transaxle Case Side
Courtesy of GENERAL MOTORS CORP.
5. Using a press, install a new tapered roller bearing of the transaxle case side.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 394: Tapered Roller Bearing & Transaxle Housing Side
Courtesy of GENERAL MOTORS CORP.
6. Using a press, install a new tapered roller bearing of the transaxle housing side.
DIFFERENTIAL ASSEMBLY DISASSEMBLE
Tools Required
DT 46463 (DW240-150) Transaxle Case Side Bearing Outer Race Adapter. See Special Tools.
DT 46465 (DW240-170) Adapter Handle. See Special Tools.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 395: Matchmarks, Ring Gear & Differential Case
Courtesy of GENERAL MOTORS CORP.
1. Place the matchmarks (1) on the ring gear and differential case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 396: Differential Assembly & Bolts
Courtesy of GENERAL MOTORS CORP.
2. Remove the 8 bolts.

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Fig. 397: Taping On Ring Gear To Remove From Case Using A Plastic Hammer
Courtesy of GENERAL MOTORS CORP.
3. Using a plastic hammer, tap on the ring gear to remove it from the case.

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