automatic transmission CHEVROLET AVEO 2002 Service Repair Manual

Tire Terminology and Denitions
Air Pressure:The amount of air inside the tire pressing
outward on each square inch of the tire. Air pressure
is expressed in pounds per square inch (psi) or
kilopascal (kPa).
Accessory Weight:This means the combined weight
of optional accessories. Some examples of optional
accessories are, automatic transmission, power steering,
power brakes, power windows, power seats, and air
conditioning.
Aspect Ratio:The relationship of a tire’s height to
its width.
Belt:A rubber coated layer of cords that is located
between the plies and the tread. Cords may be made
from steel or other reinforcing materials.
Bead:The tire bead contains steel wires that hold the
tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the plies are
laid at alternate angles, less than 90 degrees to the
centerline of the tread.Cold Ination Pressure:The amount of air pressure
in a tire, measured in pounds per square inch (psi)
or kilopascal (kPa), before a tire has built up heat from
driving. SeeInflation - Tire Pressure on page 5-59.
Curb Weight:This means the weight of a motor vehicle
with standard and optional equipment including the
maximum capacity of fuel, oil and coolant, but without
passengers and cargo.
DOT Markings:A code molded into the sidewall of a
tire signifying that the tire is in compliance with the
U.S. Department of Transportation motor vehicle safety
standards. The DOT code includes the Tire Identification
Number (TIN), an alphanumeric designator which can
also identify the tire manufacturer, production plant,
brand and date of production.
GVWR:Gross Vehicle Weight Rating, seeLoading
Your Vehicle on page 4-32.
GAWR FRT:Gross Axle Weight Rating for the front
axle, seeLoading Your Vehicle on page 4-32.
GAWR RR:Gross Axle Weight Rating for the rear axle,
seeLoading Your Vehicle on page 4-32.
5-56

Part D: Recommended Fluids
and Lubricants
Fluids and lubricants identified below by name, part
number or specification may be obtained from your
dealer.
Usage Fluid/Lubricant
Engine OilEngine oil which meets GM Standard
GM6094M and displays the
American Petroleum Institute
Certified for Gasoline Engines
starburst symbol. To determine the
proper viscosity for your vehicle’s
engine, seeEngine Oil on page 5-15.
Engine Coolant50/50 mixture of clean, drinkable
water (preferably distilled) and good
quality Ethylene Glycol Base Coolant
(GM Part No. U.S. 12378560,
in Canada 993089) and conforming
to GM Specification 1825M or
recycled coolant conforming to
GM Specification 1825M.
SeeEngine Coolant on page 5-23.
Usage Fluid/Lubricant
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake fluid.
Windshield
Washer SolventGM Optikleen
®Washer Solvent.
Power Steering
SystemDEXRON
®-III Automatic
Transmission Fluid.
Automatic
TransaxleAutomatic Transaxle Fluid ESSO
LT 71141 or TOTAL ATF H50235.
Manual
TransaxleGM Goodwrench Synthetic
Manual Transmission Fluid
(GM Part No. U.S. 12346190,
in Canada 10953477) or equivalent
SAE 75W-85 GL-4 gear oil.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241,
in Canada 10953474).
6-26

Tires (cont.)
If a Tire Goes Flat.......................................5-66
Inflation - Tire Pressure................................5-59
Inspection and Rotation................................5-60
Uniform Tire Quality Grading.........................5-63
Wheel Alignment and Tire Balance.................5-64
Wheel Replacement.....................................5-64
When It Is Time for New Tires......................5-61
Matching Transmitter(s) to Your Vehicle............... 2-5
To Use the Engine Coolant Heater....................2-21
Top Strap......................................................1-38
Top Strap Anchor Location...............................1-40
Torque Lock...................................................2-30
Towing
Recreational Vehicle.....................................4-29
Towing a Trailer..........................................4-37
Your Vehicle...............................................4-29
Transaxle
Fluid, Automatic...........................................5-21
Fluid, Manual..............................................5-21
Transaxle Operation, Automatic.........................2-22
Transaxle Operation, Manual............................2-26
Transmission, Transaxle, Transfer Case Unit
Repair Manual............................................7-11
Transportation Options...................................... 7-8
Trip Odometer................................................3-19
Trunk............................................................2-10
Turn and Lane-Change Signals.......................... 3-5
Turn Signal/Multifunction Lever........................... 3-5U
Underbody Flushing Service.............................6-23
Understanding Radio Reception........................3-43
Uniform Tire Quality Grading............................5-63
United States – Customer Assistance.................. 7-4
Used Replacement Wheels..............................5-65
Using an MP3 CD..........................................3-39
Using Cleaner on Fabric..................................5-77
Using the Rear Door Security Lock..................... 2-9
V
Vehicle
Control........................................................ 4-6
Damage Warnings........................................... iv
Loading......................................................4-32
Parking Your...............................................2-31
Symbols......................................................... iv
Vehicle Data Collection and Event Data
Recorders.................................................... 7-9
Vehicle Identification
Number (VIN).............................................5-83
Service Parts Identification Label...................5-84
Vehicle Storage..............................................5-39
Ventilation Adjustment......................................3-15
Visor Vanity Mirror..........................................2-14
Visors...........................................................2-14
13

Tire Size
The following illustration shows an example of a typical
passenger car tire size.
(A) Passenger (P-Metric) Tire:The United States
version of a metric tire sizing system. The letter P as the
first character in the tire size means a passenger
vehicle tire engineered to standards set by the U. S.
Tire and Rim Association.
(B) Tire Width:The three-digit number indicates the
tire section width in millimeters from sidewall to sidewall.
(C) Aspect Ratio:A two-digit number that indicates
the tire height-to-width measurements. For example, if
the tire size aspect ratio is 70, as shown in item C of the
illustration, it would mean that the tire’s sidewall is
70% as high as it is wide.(D) Construction Code:A letter code is used to
indicate the type of ply construction in the tire. The
letter R means radial ply construction; the letter D
means diagonal or bias ply construction; and the letter B
means belted-bias ply construction.
(E) Rim Diameter:Diameter of the wheel in inches.
(F) Service Description:These characters represent
the load range and the speed rating of a tire. The
load range represents the load carry capacity a tire is
certified to carry. The speed rating is the maximum
speed a tire is certified to carry a load. Speed ratings
range from A to Z.
Tire Terminology and Denitions
Air Pressure:The amount of air inside the tire pressing
outward on each square inch of the tire. Air pressure
is expressed in pounds per square inch (psi) or
kilopascal (kPa).
Accessory Weight:This means the combined weight
of optional accessories. Some examples of optional
accessories are, automatic transmission, power steering,
power brakes, power windows, power seats, and air
conditioning.
Aspect Ratio:The relationship of a tire’s height to its
width.
5-48

Part D: Recommended Fluids and
Lubricants
Fluids and lubricants identified below by name, part
number, or specification may be obtained from
your dealer.
Usage Fluid/Lubricant
Engine OilEngine oil which meets GM Standard
GM6094M and displays the
American Petroleum Institute
Certified for Gasoline Engines
starburst symbol. GM Goodwrench
®
oil meets all the requirements for your
vehicle. To determine the proper
viscosity for your vehicle’s engine,
seeEngine Oil on page 5-13.
Engine Coolant50/50 mixture of clean, drinkable
water (preferably distilled) and good
quality Ethylene Glycol Base Coolant
(GM Part No. U.S. 12378560, in
Canada 993089) and conforming to
GM Specification 1825M or recycled
coolant conforming to GM
Specification 1825M. SeeEngine
Coolant on page 5-22.
Usage Fluid/Lubricant
Hydraulic Brake
SystemDelco
®Supreme 11 Brake Fluid or
equivalent DOT-3 brake fluid.
Windshield
Washer SolventGM Optikleen
®Washer Solvent.
Power Steering
SystemDEXRON
®-III Automatic
Transmission Fluid. Look for
“Approved for the H-Specification”
on the label.
Automatic
TransaxleUse only T-IV Automatic
Transmission Fluid
(GM Part No. U.S. 88900925, in
Canada 22689186). SeeAutomatic
Transaxle Fluid on page 5-19.
Manual
TransaxleGM Goodwrench
®Synthetic Manual
Transmission Fluid
(GM Part No. U.S. 12346190, in
Canada 10953477) or equivalent
SAE 75W-85 GL-4 gear oil.
6-25

2006 TRANSMISSION
Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
Application
Specification
MetricEnglish
Check Valve Spring Bolts6.5 N.m57 lb in
Control Cable Adjusting Nut8 N.m71 lb in
Damping Block Connection Nut and Bolt80 N.m59 lb ft
Differential Case-to-Differential Ring Gear Bolt102 N.m75 lb ft
Drain Plug17 N.m13 lb ft
Fluid Cooler Inlet Pipe Bolt9 N.m80 lb in
Fluid Cooler Inlet Pipe Fitting Nut35 N.m26 lb ft
Fluid Cooler Rear Outlet Pipe Clip Bolt9 N.m80 lb in
Fluid Cooler Rear Outlet Pipe Fitting Nut35 N.m26 lb ft
Front Outlet Pipe Clip Bolt9 N.m80 lb in
Front Outlet Pipe Union Bolt35 N.m26 lb ft
Input Speed Sensor Retaining Bolt5.4 N.m48 lb in
Manual Detent Spring Bolt9.8 N.m87 lb in
Manual Valve Lever Shaft Nut12 N.m106 lb in
Lower Transaxle-to-Engine Retaining Bolts73 N.m54 lb ft
Lower Transaxle-to-Engine Retaining Bolts31 N.m23 lb ft
Lower Transaxle-to-Engine Retaining Bolts21 N.m15 lb ft
Oil Pan Bolts7 N.m62 lb in
Oil Pump Bolts25 N.m18 lb ft
Oil Reservoir Lock Plate Bolts5.4 N.m48 lb in
Oil Strainer Bolts9.8 N.m87 lb in
Output Speed Sensor Retaining Bolt7.4 N.m65 lb in
Park/Neutral Position Switch Bolts5.4 N.m48 lb in
Parking Lock Pawl Bracket Bolts7.4 N.m65 lb in
Planetary Ring Gear Nut-Maximum29 N.m22 lb ft
Planetary Ring Gear Nut-Standard9.8 N.m87 lb in
Rear Mounting Bracket Bolts60 N.m44 lb ft
Screw Plugs7.4 N.m65 lb in
Shift Control Lever Assembly Mounting Bolts8 N.m71 lb in
Shift Solenoid Valve Bolts11 N.m97 lb in

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

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.
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TRANSMISSION GENERAL SPECIFICATIONS
Transmission General Specifications
Washer Thickness
Shim Thickness
Stator Shaft Bolts25 N.m18 lb ft
TCM Retaining Bolts5 N.m44 lb in
Torque Converter Bolts45 N.m43 lb ft
Transaxle Apply Clamp Bolt5.4 N.m48 lb in
Transaxle Case Plate Bolt9.8 N.m87 lb in
Transaxle Housing Bolts29 N.m22 lb ft
Transaxle Rear Cover Bolts25 N.m18 lb ft
Unions25 N.m18 lb ft
Upper Transaxle Mounting Bracket Bolts60 N.m44 lb ft
Upper Transaxle-to-Engine Mounting Bolts73 N.m54 lb ft
Valve Body Bolts11 N.m97 lb in
Application
Specification
MetricEnglish
MakerAISIN
Type or Model81-40LE
Gear Ratio - 1st2.875:1
Gear Ratio - 2nd1.568:1
Gear Ratio - 3rd1.000:1
Gear Ratio - 4th0.697:1
Reverse2.300:1
Final Drive Ratio3.750:1
Oil Capacity5.6L5.9 qt
Transmission Fluid Type
T-IV Automatic Transmission Fluid (GM
Part No. U.S. 88900925, in Canada
22689186)
MetricEnglish
0.95 mm0.0374 in
1 mm0.0394 in
1.05 mm0.0413 in
1.1 mm0.0433 in
1.15 mm0.0453 in
1.2 mm0.0472 in
Specification

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

Adjuster Shim Thickness
ApplicationMetricEnglish
Mark A1.8 mm0.0709 in
Mark B1.85 mm0.0728 in
Mark C1.9 mm0.0748 in
Mark D1.95 mm0.0768 in
Mark E2 mm0.787 in
Mark F2.05 mm0.0807 in
Mark G2.08 mm0.0819 in
Mark H2.11 mm0.0831 in
Mark J2.14 mm0.0843 in
Mark K2.17 mm0.0854 in
Mark L2.2 mm0.0866 in
Mark M2.23 mm0.0878 in
Mark N2.26 mm0.089 in
Mark P2.29 mm0.0902 in
Mark Q2.32 mm0.0913 in
Mark R2.35 mm0.0925 in
Mark S2.4 mm0.0945 in
Mark T2.45 mm0.0965 in
Mark U2.5 mm0.0984 in
Mark V2.55 mm0.1004 in
Mark W2.6 mm0.1024 in
Mark X2.65 mm0.1043 in
Mark Y2.7 mm0.1063 in
Application
Specification
MetricEnglish
Mark 11.70 mm0.0669 in
Mark 21.75 mm0.0689 in
Mark 31.80 mm0.0709 in
Mark 41.85 mm0.0728 in
Mark 51.90 mm0.0748 in
Mark 61.93 mm0.0760 in
Mark 71.96 mm0.0772 in
Mark A1.99 mm0.0783 in
Mark B2.02 mm0.0795
Mark C2.05 mm0.0807 in
Mark D2.08 mm0.0819 in
Mark E2.11 mm0.0831 in
Mark F2.14 mm0.0843 in

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

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.

FLUID CAPACITY SPECIFICATIONS
Fluid Capacity Specifications
SHIFT SPEED
Fig. 1: Economic Mode (1.4/1.5L SOHC)

Courtesy of GENERAL MOTORS CORP.
Application
Specification
MetricEnglish
Transmission Fluid-Drain and Refill2.1L2.2 qt
Transmission Fluid-Dry Fill - 1.4L/1.5L/1.2L SOHC5.6L5.9 qt
Transmission Fluid-Dry Fill - 1.4L DOHC5.8L6.2 qt

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 5 © 2005 Mitchell Repair Information Company, LLC.