transmission oil CHEVROLET AVEO 2002 Service Service Manual

value.
OIL PUMP DISASSEMBLE
Fig. 318: Turning Drive Gear With 2 Screwdrivers

Courtesy of GENERAL MOTORS CORP.
1. Turn the drive
gear with 2 screwdrivers and make sure it rotates smoothly.
NOTE: Use extreme care when working around oil seals. Damage to the lip of a
seal will cause oil leaks.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:28 PMPage 331 © 2005 Mitchell Repair Information Company, LLC.

Fig. 320: Oil Pump Drive Gear
Courtesy of GENERAL MOTORS CORP.
3. Remove the oil pump drive gear and driven gear from the oil pump body.
OIL PUMP INSPECTION

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:28 PMPage 333 © 2005 Mitchell Repair Information Company, LLC.

Fig. 321: Measuring The Clearance Of Driven Gear Using A Feeler Gage
Courtesy of GENERAL MOTORS CORP.
1. Push the driven gear to one side of the body. Using a feeler gage, measure the clearance.
Specifications:
The standard body clearance is 0.1-0.17 mm (0.0039-0.0067 in).
The maximum body clearance is 0.17 mm (0.0067 in).
IMPORTANT: If the body clearance is greater than the maximum, replace the oil pump
body sub-assembly.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:28 PMPage 334 © 2005 Mitchell Repair Information Company, LLC.

Fig. 322: Measuring The Tip Clearance Between Driven Gear Teeth
Courtesy of GENERAL MOTORS CORP.
2. Measure the tip clearance between the driven gear teeth and drive gear teeth.
Specifications:
The standard tip clearance is 0.07-0.15 mm (0.0028-0.0059 in).
The maximum tip clearance is 0.15 mm (0.0059 in).
IMPORTANT: If the tip clearance is greater than the maximum, replace the oil pump
body sub-assembly.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:28 PMPage 335 © 2005 Mitchell Repair Information Company, LLC.

Fig. 324: Measuring The Inside Diameter Of Oil Pump Body Bushing Using A Dial Indicator
Courtesy of GENERAL MOTORS CORP.
4. Using a dial indicator, measure the inside diameter of the oil pump body bushing.
Specifications:
The standard inside diameter is 38.126 mm (1.50102 in).
The maximum inside diameter is 38.188 mm (1.50346 in).
IMPORTANT: If the inside diameter is greater than the maximum, replace the oil pump
body sub-assembly.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:28 PMPage 337 © 2005 Mitchell Repair Information Company, LLC.

The maximum inside diameter is 18.5 mm (0.728 in).
OIL PUMP ASSEMBLE
Fig. 326: Oil Pump Drive Gear

Courtesy of GENERAL MOTORS CORP.
1. Install the oil pump drive
gear and driven gear.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:28 PMPage 339 © 2005 Mitchell Repair Information Company, LLC.

Fig. 328: Turning Drive Gear With 2 Screwdrivers
Courtesy of GENERAL MOTORS CORP.
4. Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly.
DIRECT CLUTCH ASSEMBLY DISASSEMBLE
Tools Required
NOTE: Use extreme care when working around oil seals. Damage to the lip of a
seal will cause oil leaks.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:28 PMPage 341 © 2005 Mitchell Repair Information Company, LLC.

DT 46451 (DW240-020) Brake Clutch Spring Compressor. See Special Tools.
DT 46453 (DW240-040) Direct Clutch Adapter. See Special Tools.
Fig. 329: Using A Dial Indicator Measure The Direct Clutch Piston Stroke While Applying
Compressed Air
Courtesy of GENERAL MOTORS CORP.
1. Install the direct clutch and thrust needle roller bearing on the oil pump.
2. Using a dial indicator, measure the direct clutch piston stroke while applying and releasing 392 kPa (57
psi) of compressed air.
If the stroke is non-standard, inspect the discs, the plates, and the flan
ge.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice in
Cautions and Notices.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:28 PMPage 342 © 2005 Mitchell Repair Information Company, LLC.

Fig. 334: Direct Clutch & Oil Pump
Courtesy of GENERAL MOTORS CORP.
8. Install the direct clutch on the oil pump.
9. Apply 392 kPa (57 psi) of compressed air to the oil pump to remove the direct clutch piston.
When the piston can not be removed as it is slanted, either blow the air again with the protruding side
pushed or remove the piston usin
g needle nose pliers with vinyl tape on the tip.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice in
Cautions and Notices.
IMPORTANT: Air pressure may cause the pistons to jump-out. When removing the
piston, hold it with your hand using a waste cloth.
IMPORTANT: Do not splash ATF when air-blowing.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:28 PMPage 347 © 2005 Mitchell Repair Information Company, LLC.

Fig. 349: Using A Dial Indicator Measure The Direct Clutch Piston Stroke While Applying
Compressed Air
Courtesy of GENERAL MOTORS CORP.
11. Install the direct clutch on the oil pump.
12. Using a dial indicator, measure the direct clutch piston stroke while applying and releasing 392 kPa (57
psi) of compressed air.
Specifications: The piston stroke is 0.4-0.8 mm (0.016-0.031 in).
If the piston stroke is less than the limit of piston stroke, parts may have been assembled
incorrectly, so check and reassemble again.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice .

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:29 PMPage 361 © 2005 Mitchell Repair Information Company, LLC.