2002 CHEVROLET AVEO oil

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.

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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.

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

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

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Fig. 390: Oil Seal & Transaxle Housing
Courtesy of GENERAL MOTORS CORP.
1. Install a new outer tapered roller bearin
g race into the transaxle housing.
IMPORTANT: Press-fit the outer tapered roller bearing race until it contacts the
transaxle housing.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 403: Oil Seal & Transaxle Housing
Courtesy of GENERAL MOTORS CORP.
9. Usin
g a driver, remove the oil seal from the transaxle housing.

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Fig. 405: Counter Driven Gear Outer Tapered Roller Bearing Race & Shim
Courtesy of GENERAL MOTORS CORP.
11. Usin
g a driver, remove the oil seal of transaxle case.

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Fig. 406: Removing Transaxle Case Side Bearing Outer Race & Shim Using DT 46463 & DT 46465
Courtesy of GENERAL MOTORS CORP.
12. Using the DT 46463 (2) and the DT 46465 (1), remove the transaxle case side bearing outer race and
shim. See Special Tools
.
DIFFERENTIAL ASSEMBLY ASSEMBLE
Tools Required
DT 46462 (DW240-140) Transaxle Case Side Bearing Outer Race Adapter. See Special Tools.
DT 46465 (DW240-170) Adapter Handle. See Special Tools.
DT 46461 (DW240-130) Differential Preload Adapter. See Special Tools.
DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer. See Special Tools.
DT 47521 (DW260-031-02) Transaxle Case Oil Seal Installer. See Special Tools.

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