CHEVROLET AVEO 2002 Service Repair Manual

Fig. 408: Counter Driven Gear Outer Tapered Roller Bearing Race & Shim
Courtesy of GENERAL MOTORS CORP.
2. Install the shim to the transaxle case.
3. Install a new side bearin
g outer race into the transaxle case.
IMPORTANT: Install a shim of the same thickness as the one removed.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 409: Differential Side Gear Thrust Washers & Differential Side Gears
Courtesy of GENERAL MOTORS CORP.
4. Coat the thrust washers, side gears, pinion gears, and pinion thrust washers with automatic transmission
fluid (ATF).
5. Install the 2 differential side
gear thrust washers to 2 differential side gears.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 410: Differential Side Gears, 2 Differential Pinion Thrust Washers, And 2 Differential Side
Gear Thrust Washers
Courtesy of GENERAL MOTORS CORP.
6. Install the 2 side gears with 2 thrust washers, 2 pinion gears, and 2 pinion thrust washers into the
differential case.
7. Coat the pinion shaft with ATF.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 411: Differential Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
8. Install the pinion shaft so as to ali
gn the lock pin holes on the pinion shaft and differential case.

2006 Chevrolet Aveo
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Fig. 412: Measuring Side Gear Backlash While Holding 1 Pinion Gear Toward The Case
Courtesy of GENERAL MOTORS CORP.
9. Measure the side gear backlash while holding 1 pinion gear toward the case.
Specifications: The standard backlash is 0.05-0.2 mm (0.002-0.0079 in).
IMPORTANT: If the backlash is out of specification, install the correct thrust washer to
the side gear.
IMPORTANT:
Try to select washers of the same size for both sides.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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10. Select thrust washers which will ensure that the backlash is within the specification. Refer to
Transmission General Specifications
.
Fig. 413: Driving Pin From Ring Gear Side Using A Pin Punch & Hammer

If the backlash is not within the specification, install a thrust washer
of a different thickness.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Courtesy of GENERAL MOTORS CORP.
11. Using a hammer and punch, drive in the pin through the case and holes in the pinion shaft.
Fig. 414: Staking The Differential Case Using A Hammer & Chisel

Courtesy of GENERAL MOTORS CORP.
12. Usin
g a hammer and chisel, stake the differential case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 415: Tapered Roller Bearing & Differential Case
Courtesy of GENERAL MOTORS CORP.
13. Using a press, install the tapered roller bearing into the differential case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 416: FIPG, Tapered Roller Bearing & Differential Case
Courtesy of GENERAL MOTORS CORP.
14. Using a press, install the tapered roller bearing into the differential case.
15. Remove any formed in place gasket (FIPG) material. Do not get oil on the contacting surfaces of the
transaxle housin
g or transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 417: Differential & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
16. Install the differential to the transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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