clock CHEVROLET AVEO 2002 Service Workshop Manual

Fig. 253: Verifying Planetary Gear Turns Freely
Courtesy of GENERAL MOTORS CORP.
62. Verif
y that the planetary gear turns freely counterclockwise and locks clockwise.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 313: Turning PNP Switch Lever
Courtesy of GENERAL MOTORS CORP.
137. Turn the lever counterclockwise until the lever stops, then turn clockwise 2 notches.
138. Remove the control lever.

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Fig. 354: Turning Rear Planetary Sun Gear & One-Way Clutch
Courtesy of GENERAL MOTORS CORP.
1. Install the one-way clutch and thrust washer to the rear planetary sun gear.
2. Hold the rear planetary sun gear and turn the one-way clutch. The one-way clutch should turn freely
clockwise and should lock counterclockwise.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 360: Turning Rear Planetary Sun Gear & One-Way Clutch
Courtesy of GENERAL MOTORS CORP.
4. Install the one-way clutch and thrust washer to the rear planetary sun gear.
5. Hold the rear planetary sun gear and turn the one-way clutch. The one-way clutch should turn freely
clockwise and should lock counterclockwise.
FORWARD AND REVERSE CLUTCH DISASSEMBLE
Tools Required
DT 46451 (DW240-020) Brake/Clutch Spring Compressor. See Special Tools.
DT 46452 (DW240-030) Forward Clutch Adapter. See Special Tools.
DT 46520 (DW240-120) Measuring Terminal. See Special Tools.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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A. Front Planetary Gear
B. Rear Planetary Gear
D - 4th Gear
1. The input shaft rotates clockwise.
The direct clutch (C2) operates. Connect the input shaft to the planetary carrier.
2. The planetary carrier revolves clockwise.
3. The planetary long pinion rotates itself clockwise.
4. The rear planetary sun gear is going to rotate counterclockwise.
The O/D and 2nd brake (B1) operates. Lock rotates the planetary sun gear.
5. The planetary long pinion revolves clockwise while rotating itself clockwise.
6. The ring gear rotates clockwise.
7. The counter drive gear rotates clockwise for the ring gear and one.
8. The counter driven gear rotates counterclockwise.
9. The differential gear drive pinion rotates counterclockwise for the counter driven gear and one.
10. The differential gear rotates clockwise.
Engine Brake
The driving force is connected to the input shaft directory without the 1-way clutch. Therefore the engine brake
operates.
MANUAL THIRD GEAR
Manual Third Gear
Position
SolenoidClutchBrake1-Way Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
D3rdOFFOFFOFFONONOFFOFFONOFFOFFOFF

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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1. The input shaft rotates clockwise.
The forward clutch (C1) operates. Connect the input shaft to the front sun gear.
The direct clutch (C2) operates. Connect the input shaft to the planetary carrier.
2. The planetary short pinion and the planetary long pinion can not rotate itself, and the planetary gear unit
rotates clockwise as one.
3. The counter drive gear rotates clockwise for the ring gear and one.
4. The counter drive gear rotates counterclockwise.
5. The differential drive pinion rotates counterclockwise for the counter driven gear and one.
6. The differential rotates clockwise.
Engine Brake
The driving force is connected to the input shaft directory without the 1-way clutch. Therefore the engine brake
operates.
MANUAL SECOND GEAR
Manual Second Gear
Position
SolenoidClutchBrake1-Way Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
D2ndONOFFOFFONOFFOFFOFFONOFFONOFF
22ndONOFFOFFONOFFOFFONONOFFONOFF

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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D - 2nd Gear
1. The input shaft rotates clockwise.
The forward clutch (C1) operates. Connect the input shaft to the front sun gear.
2. The front sun gear rotates clockwise.
3. The planetary short pinion rotates itself counterclockwise.
4. The planetary long pinion rotates itself clockwise.
5. The rear planetary sun gear is going to rotate counterclockwise.
The 2nd brake (B2) and 1-way clutch No. 1 operates, lock counterclockwise rotation of the rear planetary
sun gear.
6. The planetary carrier revolves clockwise due to reaction force of the planetary long pinion.
7. The ring gear rotates clockwise.
8. The counter drive gear rotates clockwise for the ring gear and one.
9. The counter driven gear rotates counterclockwise.
10. The differential gear drive pinion rotates counterclockwise for the counter driven gear and one.
11. The differential gear rotates clockwise.
Engine Brake
1. The counter drive gear and planetary ring gear rotates counterclockwise.
2. The planetary long pinion rotates itself counterclockwise.
3. The planetary short pinion rotates itself clockwise.
4. The rear sun gear rotates clockwise due to rotation itself counterclockwise of the planetary long pinion,
but the driving force loses due to free to 1-way clutch No. 1 (F1). Therefore the engine brake does not
operate.
MANUAL FIRST GEAR
Manual First Gear
Position
SolenoidClutchBrake1-Way Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
D1stONONOFFONOFFOFFOFFOFFOFFOFFON
11stONONOFFONOFFOFFOFFOFFONOFFON

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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1. The input shaft rotates clockwise.
The forward clutch (C1) operates. Connect the input shaft to the front sun gear.
2. The front sun gear rotates clockwise.
3. The planetary short pinion rotates itself counterclockwise.
4. The planetary long pinion rotates itself clockwise.
5. The planetary carrier is going to rotate counterclockwise.
The one-way clutch No. 2 (F2) operates. The lock revolves counterclockwise of the planetary carrier.
6. The ring gear rotates clockwise.
7. The counter drive gear rotates clockwise for ring gear and one.
8. The counter drive gear rotates counterclockwise.
9. The differential gear drive pinion rotates counterclockwise for the counter driven gear and one.
10. The differential gear rotates clockwise.
Engine Brake
1. The counter drive gear and planetary ring gear rotates counterclockwise.
2. The planetary long pinion rotates itself counterclockwise.
3. The planetary short pinion rotates itself clockwise.
4. The planetary carrier revolves clockwise due to rotation itself counterclockwise of the planetary long
pinion, but driving force loses due to free of 1-way clutch No. 2 (F2). Therefore the engine brake does not
operate.
REVERSE
Reverse
Position
SolenoidClutchBrake1-W
Shift 1Shift 2TimingC1C2C3B1B2B3F1
R
V is
less
than 9
km/h
(5
mph)
ONONONOFFOFFONOFFOFFONOF

V is
greater
than
or
equal
ONONONOFFOFFOFFOFFOFFOFF OF

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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A. Front Planetary Gear
B. Rear Planetary Gear
Reverse Gear
1. The input shaft rotates clockwise.
The reverse clutch (C3) operates. Connect the input shaft to the rear planetary sun gear.
2. The planetary long pinion rotates itself counterclockwise.
3. The 1st and reverse brake (3) operates. Lock rotates the planetary carrier.
4. The ring gear rotates counterclockwise.
5. The counter drive gear rotates counterclockwise for the ring gear and one.
6. The counter driven gear rotates clockwise.
7. The differential gear drive pinion rotates clockwise for the counter driven gear and one.
8. The differential gear rotates counterclockwise.
Engine Brake
The driving force is connected to the input shaft directory without the 1-way clutch. Therefore the engine brake
operates.
TRANSMISSION GENERAL DESCRIPTION
The new automatic transmission AISIN (81-40LE) is an electronically controlled 4-speed automatic
transmission with lock-up mechanism.
The transmission is mainly composed of the torque converter with lock up clutch, newly developed 4-speed
planetary gear unit, the hydraulic control system and the electric control system.
Hydraulic Control System
Based on the hydraulic pressure created by the oil pump, the TCM sends signals to the solenoid and the
hydraulic control system governs the hydraulic pressure acting on the torque converter, planetary gear, clutches,
and brakes in accordance with the vehicle driving conditions.
Function of Components
NOTE: Lack of basic knowledge of this powertrain when performing diagnostic
procedures could result in incorrect diagnostic performance or damage to
powertrain components. Do not attempt to diagnose a powertrain problem
without this basic knowledge.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 448: Function Of Components
Courtesy of GENERAL MOTORS CORP.
Function of Components
ComponentFunction
7Forward ClutchConnects the input shaft and front sun gear.
3Direct ClutchConnects the input shaft and planetary carrier.
5Reverse ClutchConnects the input shaft and rear sun gear.
6O/D and 2nd BrakePrevents rear planetary sun gear from turning
either clockwise or counterclockwise.
42nd Brake
Prevents outer race of 8 from turning either
clockwise or counterclockwise, thus
preventing the rear sun gear turning

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