CHEVROLET AVEO 2002 Service Repair Manual

Fig. 418: Transaxle Housing
Courtesy of GENERAL MOTORS CORP.
17. Install the transaxle housing and 16 bolts of the transaxle housing temporarily.
18. Tighten 8 or 9 bolts out of the 16 bolts of the transaxle housing completely.
Tighten: Ti
ghten the bolts to 29 N.m (22 lb ft).
NOTE: Refer to Fastener Notice in Cautions and Notices.

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Fig. 419: Turning The Differential Gear Assembly
Courtesy of GENERAL MOTORS CORP.
19. Using the DT 46461 , turn the differential gear assembly right and left 2-3 times to allow the bearing to
settle. See Special Tools
.

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Fig. 420: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
Courtesy of GENERAL MOTORS CORP.
20. Using the DT 46461 and a small torque wrench, measure the preload of the differential gear. See Special
Tools.
Specifications:
New bearing preload is 0.78-1.37 N.m (6.9-12.2 lb in).
Used bearing preload is 0.39-0.69 N.m (3.5-6.1 lb in).
21. Re-select the transaxle case side adjusting the shim according to the shim thickness table. Refer to
Transmission General Specifications
.
IMPORTANT: If the preload is not within specifications, remove the differential from the
transaxle case.

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Fig. 421: Transaxle Housing
Courtesy of GENERAL MOTORS CORP.
22. Usin
g a plastic hammer, remove the 16 bolts and transaxle housing.

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Fig. 422: Differential & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
23. Remove the differential gear from the transaxle case.

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Fig. 423: Ring Gear & Differential Case
Courtesy of GENERAL MOTORS CORP.
24. Clean the contact surface of the differential case.
25. Heat the ring gear in water and boil for 10 minutes.
26. Carefully remove the ring gear from the water.
27. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the
differential case.

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Fig. 424: Differential Assembly & Bolts
Courtesy of GENERAL MOTORS CORP.
28. Install the 8 bolts.
Tighten: Tighten the bolts to 102 N.m (75 lb ft).

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Fig. 425: Driving In A Transaxle Housing Oil Seal Using A Hammer & DT 46471
Courtesy of GENERAL MOTORS CORP.
29. Using the DT 46471 (1) and a hammer, drive in a new transaxle housing oil seal. See Special Tools
.
Specifications: The oil seal in depth is 3.1 mm (0.122 in).

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Fig. 426: Driving In A Transaxle Case Oil Seal Using A Hammer & DT 46471
Courtesy of GENERAL MOTORS CORP.
30. Using the DT 47521 (1), drive in a new transaxle case oil seal. See Special Tools
.
Specifications: The oil seal in depth is 4.3 mm (0.169 in).
CONTROL VALVE BODY DISASSEMBLE

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Fig. 427: Primary Regulator Valve Sleeve, Plug & Pin
Courtesy of GENERAL MOTORS CORP.
1. Write down the relative position of the primary regulator valve sleeve, plug, and pin.
2. Remove the manual valve.
IMPORTANT: Because the line pressure is changed by the position of the pin and
groove in the sleeve end, be sure to check the position.

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