transmission fluid CHEVROLET AVEO 2002 Service Owner's Guide

Filling Procedure
Fig. 124: Fluid Level & Dipstick
Courtesy of GENERAL MOTORS CORP.
1. Remove the drainage container and lower the vehicle.
2. Add 3/4 of the recommended amount of T-IV Automatic Transmission Fluid.
3. Start the engine and allow it to reach normal operating temperature.
4. Shift the gear selector through all positions.

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5. Check the fluid level and add fluid until the dipstick indicates a safe level.
TRANSMISSION DISASSEMBLE
Tools Required
DT 46451 (DW240-020) Brake/Clutch Spring Compressor. See Special Tools.
DT 46454 (DW240-050) Overdrive Brake Adapter. See Special Tools.
DT 46455 (DW240-060-01) Brake Spring Compressor Bolt/Nut. See Special Tools.
DT 46457 (DW240-070) 1st and Reverse Brake Adapter. See Special Tools.
DT 46463 (DW240-150) Transaxle Case Side Bearing Outer Race Adapter. See Special Tools.
DT 46465 (DW240-170) Adapter Handle. See Special Tools.
DT 46453 (DW260-021) Automatic Transaxle Overhaul Fixture. See Special Tools.
DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket. See Special Tools.
Disassembly Procedure
IMPORTANT: The correct fluid level must be between the HOT MIN (2) and the HOT MAX
(1) notches on the dipstick.

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Fig. 134: Solenoid Connectors
Courtesy of GENERAL MOTORS CORP.
19. Remove the bolt and transmission fluid temperature sensor with the clamp.
20. Disconnect the 5 solenoid connectors.
Lock-up control solenoid (5)
Pressure control solenoid (1)
No. 2 shift solenoid (2)
No. 1 shift solenoid (3)
Timing solenoid (4)

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Fig. 140: Applying Compressed Air To Oil Hole & Removing Direct Clutch Accumulator Piston &
Spring.
Courtesy of GENERAL MOTORS CORP.
26. Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the direct clutch accumulator
piston and spring.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice .
IMPORTANT:
Air pressure may cause the pistons to jump out. When removing the
piston, hold it in place with your hand using a waste cloth.
Take care not to splash automatic transaxle fluid (ATF) when air-
blowing.

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Fig. 207: O-Rings & O/D Brake Piston
Courtesy of GENERAL MOTORS CORP.
5. Coat 2 new O-rings (1) with automatic transaxle fluid (ATF). Install the O-rings to the O/D brake piston.

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Fig. 342: O-Ring & Input Shaft
Courtesy of GENERAL MOTORS CORP.
2. Coat a new O-ring (1) with automatic transmission fluid (ATF) and install the O-ring to the input shaft.

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Fig. 369: Forward/Reverse Multiple Disc Clutch & Transaxle Rear Cover
Courtesy of GENERAL MOTORS CORP.
12. Install the forward and reverse multiple disc clutch on the transaxle rear cover.
13. Apply 392 kPa (57 psi) of compressed air to the transaxle rear cover to remove the forward clutch piston.
When the piston cannot be removed as it is slanted, either blow the air again with the protruding side
pushed or remove the piston usin
g a needle-nose pliers with vinyl tape on the tip.
IMPORTANT:Air pressure may cause the pistons to jump-out. When removing the
piston, hold it with your hand using a waste cloth.
Take care not to splash automatic transmission fluid (ATF) when air-
blowing.

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Fig. 375: O-Ring & Intermediate Shaft Sub-Assembly
Courtesy of GENERAL MOTORS CORP.
1. Coat a new O-ring (1) with automatic transmission fluid (ATF) and install it to the intermediate shaft sub-
assembly.

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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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ELECTRONIC COMPONENT DESCRIPTION
Transmission Control Module (TCM)
The transmission control module (TCM) primarily controls shift points and lockup engagement. It is located on
the driver side under the instrument panel.
The transmission is controlled by an electronic shift system. The TCM processes input signals. From the
information received, the TCM controls the transmission hydraulic system.
The electronic shift system consists of the following components.
TCM
Shift solenoids (SS1 and SS2)
Pressure control solenoid (PCS)
Lockup solenoid
Input shaft speed (ISS) sensor
Output shaft speed (OSS) sensor
Transmission fluid temperature (TFT) sensor
Park/neutral position (PNP) switch
Park/Neutral Position (PNP) Switch
The PNP switch transmits the information which range includes the shift lever of the automatic transmission
(A/T) to the starter and TCM.
It is possible for the PNP switch to start an engine in only park (P) and neutral (N) prevention of reckless
driving
The PNP switch makes the backup lamp turn on when reversing.
It is used for PNP switch to shift control.
The PNP switch transmits the information by combination of starter and reverse circuit to the vehicle side
directl
y without TCM.

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