clutch CHEVROLET AVEO 2002 Service Service Manual

Cleaning
Aluminum Wheels........................................5-71
Exterior Lamps/Lenses.................................5-69
Fabric/Carpet..............................................5-67
Finish Care.................................................5-70
Inside of Your Vehicle..................................5-66
Instrument Panel, Vinyl, and Other Plastic
Surfaces.................................................5-68
Tires..........................................................5-71
Underbody Maintenance...............................5-72
Washing Your Vehicle...................................5-69
Weatherstrips..............................................5-69
Windshield and Wiper Blades........................5-70
Climate Control System...................................3-18
Air Filter, Passenger Compartment.................3-21
Outlet Adjustment........................................3-21
Clock............................................................3-32
Clutch, Hydraulic.............................................5-21
Collision Damage Repair..................................7-11
Compact Spare Tire........................................5-66
Control of a Vehicle.......................................... 4-6
Coolant
Engine Temperature Gage............................3-28
Heater, Engine............................................2-20
Surge Tank Pressure Cap.............................5-24
Cooling System..............................................5-26
Cruise Control................................................3-10
Cruise Control Light........................................3-29
Cupholder(s)..................................................2-34Customer Assistance Information
Courtesy Transportation.................................. 7-8
Customer Assistance for Text
Telephone (TTY) Users............................... 7-4
Customer Assistance Offices........................... 7-4
Customer Satisfaction Procedure..................... 7-2
GM Mobility Reimbursement Program............... 7-6
Reporting Safety Defects to General Motors....7-15
Reporting Safety Defects to the
Canadian Government..............................7-14
Reporting Safety Defects to the
United States Government.........................7-14
Roadside Assistance Program......................... 7-6
Service Publications Ordering Information........7-15
D
Daytime Running Lamps..................................3-14
Daytime Running Lamps Indicator Light.............3-29
Defensive Driving............................................. 4-2
Doing Your Own Service Work........................... 5-4
Dome Lamp ...................................................3-16
Door
Ajar Light...................................................3-38
Central Door Unlocking System....................... 2-7
Door Ajar Reminder....................................... 2-8
Locks.......................................................... 2-7
Rear Door Security Locks............................... 2-8
3

Fuel............................................................... 5-5
Additives...................................................... 5-6
California Fuel.............................................. 5-5
Filling a Portable Fuel Container..................... 5-9
Filling Your Tank........................................... 5-7
Fuels in Foreign Countries.............................. 5-6
Gage .........................................................3-30
Gasoline Octane........................................... 5-5
Gasoline Specifications.................................. 5-5
Low Warning Light.......................................3-30
System Inspection.......................................6-23
Fuses
Engine Compartment Fuse Block...................5-77
Fuses and Circuit Breakers...........................5-75
Instrument Panel Fuse Block.........................5-76
Windshield Wiper.........................................5-75
G
Gage
Engine Coolant Temperature.........................3-28
Fuel..........................................................3-30
Speedometer..............................................3-25
Tachometer.................................................3-25
Gasoline
Octane........................................................ 5-5
Specifications............................................... 5-5
Glove Box.....................................................2-34
GM Mobility Reimbursement Program.................. 7-6
H
Hazard Warning Flashers................................... 3-6
Head Restraints............................................... 1-5
Headlamp
Aiming .......................................................5-39
Headlamp Wiring............................................5-75
Headlamps....................................................5-40
Bulb Replacement.......................................5-40
Daytime Running Lamps...............................3-14
Flash-to-Pass............................................... 3-8
Front Turn Signal and Parking Lamps.............5-42
Halogen Bulbs............................................5-40
High/Low Beam Changer................................ 3-8
On Reminder..............................................3-13
Turn Signal Lamps......................................5-42
Heater...........................................................3-18
Height Adjuster, Driver Seat............................... 1-3
Highbeam On Light.........................................3-29
Highway Hypnosis...........................................4-20
Hill and Mountain Roads..................................4-20
Hold Mode Light.............................................3-34
Hood
Checking Things Under................................5-10
Release.....................................................5-10
Horn ............................................................... 3-6
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-17
Hydraulic Clutch.............................................5-21
5

Flange Thickness
Accumulator Spring
TRANSMISSION GEAR RATIO
Transmission Gear Ratio
Mark G2.17 mm0.0854 in
Mark H2.20 mm0.0866 in
Mark K2.25 mm0.0886 in
Mark L2.30 mm0.0906 in
Mark M2.35 mm0.0925 in
Mark N2.40 mm0.0945 in
Mark P2.45 mm0.0965 in
Mark Q2.50 mm0.0984 in
Mark R2.55 mm0.1004 in
Mark S2.60 mm0.1024 in
Mark U2.65 mm0.1043 in
Mark W2.70 mm0.1063 in
MarkPiston StrokeThickness
MetricEnglishMetricEnglish
00.738-0.949 mm0.02905-0.03736 in3.0 mm0.118 in
10.950-1.149 mm0.03740-0.04524 in3.2 mm0.126 in
21.150-1.349 mm0.04528-0.05311 in3.4 mm0.134 in
31.350-1.549 mm0.05315-0.06098 in3.6 mm0.142 in
01.550-1.702 mm0.06102-0.06701 in3.8 mm0.150 in
Spring
Free length Outer Diameter
ColorMetricEnglish
O/D and 2nd brake47.13 mm/16.0 mm1.8555 in/0.630 inPink
Forward Clutch57.90 mm/17.2 mm2.2795 in/0.677 in-
Direct Clutch57.20 mm/17.5 mm2.2520 in/0.689 inGreen
GearRatio
First2.875
Second1.568
Third1.000
Fourth0.697
Reverse2.300
Counter1.019
Differential 1.4L/1.5L/1.2L SOHC3.750
Differential 1.4L DOHC4.052

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.

10O-Ring
11Transaxle Wire
12Torsion Spring
13Transaxle Oil Apply Pipe Clamp
14Parking Lock Pawl
15Manual Valve Lever
16Spacer
17Oil Seal
18Park/Neutral Position Switch
19Lock Washer
20Control Lever
21Washer
22Spring
23O-Ring
24Overdrive Brake Accumulator Piston
25O-Ring
26Spring
27O-Ring
28Forward Clutch Accumulator Piston
29O-Ring
30O-Ring
31Direct Clutch Accumulator Piston
32O-Ring
33Spring
34Manual Detent Spring
35Pin
36Parking Lock Rod
37Parking Lock Pawl Shaft
38Manual Valve Lever Shaft
39Parking Lock Pawl Bracket
40Oil Pan
41Gasket
42Magnet
43Oil Strainer
44Gasket
45Valve Body

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 23 © 2005 Mitchell Repair Information Company, LLC.

9Snap Ring
10Planetary Gear
11Thrust Washer
12No. 2 One-Way Clutch
13Anti-Rattle Clip
14Flange
15Disc
16Plate
172nd Brake Piston Return Spring
18O-Ring
192nd Brake Piston
20O-Ring
212nd Brake Clutch Cylinder
22Snap Ring
23Thrust Bearing Race
24Front Planetary Sun Gear
25Thrust Bearing Race
26One-Way Clutch Assembly
27Thrust Washer
28Rear Planetary Sun Gear
29Snap Ring
30Flange
31Disc
32Plate
33Thrust Bearing Race
34Thrust Needle Roller Bearing
35Forward Clutch Hub
36Thrust Bearing Race
37Thrust Needle Roller Bearing
38Thrust Bearing Race
39Forward and Reverse Clutch Assembly
40Thrust Needle Roller Bearing
41Snap Ring
42O/D Brake Return Spring
43O/D Brake Piston
44O-Ring
45Seal Ring
46Transaxle Rear Cover
47Apply Gasket
48O-Ring
49Screw Plug

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 25 © 2005 Mitchell Repair Information Company, LLC.

Fig. 24: Differential And Oil Pump Component View
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 24
CalloutComponent Name
1Side Bearing Outer Race
2Shim
3Outer Tapered Roller Bearing Race
4Counter Driven Gear
5Oil Seal
6Transaxle Case Plate
7Apply Gasket
8Counter Driven Gear
9Direct Clutch Hub
10Thrust Bearing Race
11Direct Clutch Assembly
12Thrust Needle Roller Bearing
13Differential Case
14Oil Pump

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

CONNECTOR END VIEWS
Automatic Transmission Connector
2Select Control Lever Assembly
3Bolt
4Cable Fastener
5Clamp
6E-Ring
7Bolt
8Select Control Cable
9Shift Program Switch
10Shift Indicator Lamp
Connector Part InformationYazaki 7283-1407-40
10-Way (GY)
PinWire ColorCircuit No.Function
1PU898Transmission Fluid Temperature Sensor
Signal
2PK1224Timing Valve Control
3RD1226Pressure Control Solenoid Control
4D-BU1225Torque Converter Clutch Solenoid Control
5L-GN1222Shift Solenoid 1 Valve Control
6OG/BK586Transmission Fluid Temperature Sensor Low
Reference
7--Not Used
8YE/BK1227Low Reference
9--Not Used

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 29 © 2005 Mitchell Repair Information Company, LLC.

Transmission Control Module (TCM) B
Connector Part InformationAMP 1318756-1
24-Way F 025/090 SER 26POS PLUG ASSY (WH)
PinWire ColorCircuit No.Function
1BK/WH51Ground
2YE/BK1227Low Reference
3--Not Used
4RD1226Pressure Control Solenoid Control
5D-BU1225Torque Converter Clutch Solenoid Control
6PK839Ignition 1 Voltage
7YE710CAN Serial Data Low
8-10--Not Used
11PU898Transmission Fluid Temperature Sensor
Signal
12OG/BK586Transmission Fluid Temperature Sensor Low
Reference
13--Not Used
14PK1224Timing Valve Control
15YE/BK1223Shift Solenoid 2 Valve Control
16L-GN1222Shift Solenoid 1 Valve Control
17PU1807CAN Serial Data High
18-22--Not Used
23BK/WH51Ground
24OG440Battery Positive Voltage

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 33 © 2005 Mitchell Repair Information Company, LLC.

Fig. 27: Upper Valve Body Spring Component View
Courtesy of GENERAL MOTORS CORP.
Automatic Transmission Components
MarkNameColorFree LengthOuter DiameterTotal
Number of
Coils
MetricEnglishMetricEnglish
13-4 Shift
ValveRed25.5 mm1.0039 in9.73 mm0.3831 in7.75
2
Lock Up
Control
Valve
Yellow20.87 mm0.8217 in5.55 mm0.2185 in11.15
3
Reverse
Control
Valve
-25.58 mm1.0071 in8.64 mm0.3402 in8.75
4
Secondary
Regulator
Valve
White34.56 mm1.3606 in8.8 mm0.346 in12.27
5
Reverse
Clutch
Accumulator
-65.4 mm2.5748 in17 mm0.669 in13.7

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 36 © 2005 Mitchell Repair Information Company, LLC.

REPAIR INSTRUCTIONS
TRANSMISSION FLUID TEMPERATURE SENSOR REPLACEMENT
Removal Procedure
1. Drain the transaxle fluid from the transaxle. Refer to Draining Transmission Fluid.
DTC P0977 Shift Solenoid 2 (SS2) Open or Short
to Power
DTC P1701 or P1792 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P1701 or P1792 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P1702 (Non European or N. American Emissions) ** MULTIPLE VALUES **
DTC P1702 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P1781 Malfunction of Engine Speed Signal
DTC P1791 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P1791 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P2769 Torque Converter Clutch (TCC)
Electrical (Ground Short)
DTC P2770 Torque Converter Clutch (TCC)
Electrical (Open or Short to Power)
DTC U0401 TCM Received Invalid Data from
ECM
DTC U2105 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC U2105 (Europe and N. American Emissions) ** MULTIPLE VALUES **
IMPORTANT: The Transmission Fluid Temperature (TFT) sensor is incorporated into the
wiring harness assembly. The harness and sensor have to be replaced as an
assembly

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 43 © 2005 Mitchell Repair Information Company, LLC.