2002 CHEVROLET AVEO differential

Fig. 195: No. 1 Transaxle Apply Pipe Clamp
Courtesy of GENERAL MOTORS CORP.
86. Remove the bolt and No. 1 transaxle apply pipe clamp from the transaxle housing.
87. Remove the transaxle lube appl
y pipe and differential gear lube apply pipe from the transaxle housing.

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DT 46457 DW240-070) 1st/Reverse Brake Adapter. See Special Tools.
DT 46458 (DW240-080) 2nd Brake Adapter. See Special Tools.
DT 46460 (DW240-100) Counter Drive Gear Installation Adapter. See Special Tools.
DT 46461 (DW240-130) Differential Preload Adapter. See Special Tools.
DT 46462 (DW240-140) Transaxle Housing Side Bearing Outer Race Adapter. See Special Tools.
DT 46464 (DW240-160) Transaxle Case Outer Tapered Roller Bearing Race Adapter. See Special Tools.
DT 46465 (DW240-170) Adapter Handle. See Special Tools.
DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer. See Special Tools.
DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket. See Special Tools.
DT 47521 (DW260-031-02) Transaxle Case Oil Seal Installer. See Special Tools.
Assembly Procedure

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Fig. 213: No. 1 Transaxle Apply Pipe Clamp
Courtesy of GENERAL MOTORS CORP.
11. Install the transaxle lube apply pipe and differential gear lube apply pipe to the transaxle housing.
12. Install the No. 1 transaxle apply pipe clamp to the transaxle housing with the bolt.
Tighten: Ti
ghten the bolts to 5.4 N.m (48 lb in).

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Fig. 219: Differential Gear & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
20. Install the differential
gear to the transaxle case.

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Fig. 221: Turning The Differential Gear Assembly
Courtesy of GENERAL MOTORS CORP.
23. Using DT 46461 , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to
settle. See Special Tools
.

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Fig. 222: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
Courtesy of GENERAL MOTORS CORP.
24. Using DT 46461 and a small torque wrench, measure the preload of the differential gear. See Special
Tools.
IMPORTANT: Note the measured value.

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Fig. 225: Turning The Differential Gear Assembly
Courtesy of GENERAL MOTORS CORP.
28. Using DT 46461 , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to
settle. See Special Tools
.

2006 Chevrolet Aveo
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Fig. 226: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
Courtesy of GENERAL MOTORS CORP.
29. Using DT 46461 and a small torque wrench, measure the preload of the differential gear. See Special
Tools. From this value deduct the value measured previously. This new value is the preload of the
counter driven gear.
Specification:
The preload for a new bearing is 0.33-0.76 N.m (3.21-6.77 lb in).
The preload for a used bearing is 0.17-0.38 N.m (1.48-3.39 lb in).
30. If the preload of the counter driven gear does not satisfy the specification, select the adjuster shim from
the table below and re-measure the value. Until the value is within the specification, repeat the procedure.
IMPORTANT: When the preload is larger than the specification, select a thinner adjuster
shim. When the preload is smaller than specification, select a thicker
adjuster shim.

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