2002 CHEVROLET AVEO brake

Light (cont.)
Malfunction Indicator....................................3-34
Oil Pressure...............................................3-37
Passenger Airbag Status Indicator..................3-26
Safety Belt Reminder...................................3-32
Safety Belt Reminder Tone...........................3-25
Loading Your Vehicle.......................................4-27
Lockout Protection............................................ 2-9
Locks
Central Door Unlocking System....................... 2-7
Door ........................................................... 2-7
Lockout Protection......................................... 2-9
Rear Door Security Locks............................... 2-8
Long Trip/Highway Scheduled Maintenance........6-13
Loss of Control...............................................4-13
Low Fuel Warning Light...................................3-30
M
Maintenance, Normal Replacement Parts............5-81
Maintenance Schedule
At Each Fuel Fill.........................................6-18
At Least Once a Month................................6-18
At Least Once a Year..................................6-20
At Least Twice a Year..................................6-19
Brake System Inspection..............................6-24
Engine Cooling System Inspection.................6-24
Exhaust System Inspection...........................6-23
Fuel System Inspection................................6-23Maintenance Schedule (cont.)
How This Section is Organized....................... 6-3
Introduction.................................................. 6-2
Long Trip/Highway Scheduled Maintenance.....6-13
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4
Part B - Owner Checks and Services.............6-18
Part C - Periodic Maintenance Inspections......6-23
PartD-Recommended Fluids and Lubricants....6-25
PartE-Maintenance Record........................6-27
Selecting the Right Schedule.......................... 6-5
Short Trip/City Scheduled Maintenance............. 6-6
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection..........................6-23
Using.......................................................... 6-4
Your Vehicle and the Environment................... 6-2
Malfunction Indicator Light................................3-34
Manual Seats................................................... 1-2
Manual Transaxle
Fluid..........................................................5-21
Operation...................................................2-25
Manual Windows............................................2-12
Mirrors
Manual Rearview Mirror................................2-32
Outside Convex Mirror.................................2-33
Outside Heated Mirrors................................2-33
Outside Manual Mirrors................................2-32
Outside Power Mirror...................................2-33
MyGMLink.com................................................ 7-4
7

N
New Vehicle Break-In......................................2-17
Normal Maintenance Replacement Parts............5-81
O
Odometer......................................................3-25
Odometer, Trip...............................................3-25
Off-Road Recovery..........................................4-11
Oil
Engine.......................................................5-13
Pressure Light.............................................3-37
Older Children, Restraints................................1-30
Online Owner Center........................................ 7-4
Other Warning Devices...................................... 3-6
Outlet Adjustment............................................3-21
Outlet(s), Accessory Power...............................3-16
Outside
Convex Mirror.............................................2-33
Heated Mirrors............................................2-33
Manual Mirrors............................................2-32
Power Mirror...............................................2-33
Owners, Canadian............................................... ii
P
Paint, Damage...............................................5-72
Park (P)
Shifting Into................................................2-27
Shifting Out of............................................2-28
Parking
Brake........................................................2-26
Over Things That Burn.................................2-30
Parking Your Vehicle.......................................2-29
Part A - Scheduled Maintenance Services............ 6-4
Part B - Owner Checks and Services................6-18
Part C - Periodic Maintenance Inspections..........6-23
Part D - Recommended Fluids and Lubricants....6-25
PartE-Maintenance Record...........................6-27
Passenger Airbag Status Indicator.....................3-26
Passenger Compartment Air Filter.....................3-21
Passenger Sensing System..............................1-65
Passing.........................................................4-11
Power
Accessory Outlet(s)......................................3-16
Electrical System.........................................5-75
Steering Fluid.............................................5-30
Windows....................................................2-13
Pretensioners, Safety Belt................................1-29
8

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.

Fig. 22: Case And Associated Parts (2 of 2)
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 22
CalloutComponent Name
1Oil Seal
2Transaxle Housing
3Oil Reservoir Plate
4Transaxle Oil Apply Pipe
5Spring
6Check Valve Pipe Clamp
7Apply Gasket
8Brake Drum Gasket
9Differential Gear Oil Apply Pipe

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 22 © 2005 Mitchell Repair Information Company, LLC.

10O-Ring
11Transaxle Wire
12Torsion Spring
13Transaxle Oil Apply Pipe Clamp
14Parking Lock Pawl
15Manual Valve Lever
16Spacer
17Oil Seal
18Park/Neutral Position Switch
19Lock Washer
20Control Lever
21Washer
22Spring
23O-Ring
24Overdrive Brake Accumulator Piston
25O-Ring
26Spring
27O-Ring
28Forward Clutch Accumulator Piston
29O-Ring
30O-Ring
31Direct Clutch Accumulator Piston
32O-Ring
33Spring
34Manual Detent Spring
35Pin
36Parking Lock Rod
37Parking Lock Pawl Shaft
38Manual Valve Lever Shaft
39Parking Lock Pawl Bracket
40Oil Pan
41Gasket
42Magnet
43Oil Strainer
44Gasket
45Valve Body

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 23 © 2005 Mitchell Repair Information Company, LLC.

Fig. 23: Internal Components View
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 23
CalloutComponent Name
1Planetary Ring Gear
2O-Ring
31st and Reverse Brake Piston
4O-Ring
51st and Reverse Brake Piston Return Spring
6Plate
7Disc
8Flange

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 24 © 2005 Mitchell Repair Information Company, LLC.

9Snap Ring
10Planetary Gear
11Thrust Washer
12No. 2 One-Way Clutch
13Anti-Rattle Clip
14Flange
15Disc
16Plate
172nd Brake Piston Return Spring
18O-Ring
192nd Brake Piston
20O-Ring
212nd Brake Clutch Cylinder
22Snap Ring
23Thrust Bearing Race
24Front Planetary Sun Gear
25Thrust Bearing Race
26One-Way Clutch Assembly
27Thrust Washer
28Rear Planetary Sun Gear
29Snap Ring
30Flange
31Disc
32Plate
33Thrust Bearing Race
34Thrust Needle Roller Bearing
35Forward Clutch Hub
36Thrust Bearing Race
37Thrust Needle Roller Bearing
38Thrust Bearing Race
39Forward and Reverse Clutch Assembly
40Thrust Needle Roller Bearing
41Snap Ring
42O/D Brake Return Spring
43O/D Brake Piston
44O-Ring
45Seal Ring
46Transaxle Rear Cover
47Apply Gasket
48O-Ring
49Screw Plug

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 25 © 2005 Mitchell Repair Information Company, LLC.

Fig. 28: Upper Valve Body Key Component View
Courtesy of GENERAL MOTORS CORP.
Automatic Transmission Components
Piston
6
2nd Brake
Accumulator
Piston -
Outer
White69 mm2.7165 in16 mm0.63 in15.1
7
2nd Brake
Accumulator
Piston - Inner
-45.9 mm1.8071 in10.5 mm0.413 in16.9
8
3-4 Shift
Timing
Valve
Pink28.41 mm1.1185 in6.4 mm0.252 in10.49
MarkRetainerHeightWidthThickness
MetricEnglishMetricEnglishMetricEnglish

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 37 © 2005 Mitchell Repair Information Company, LLC.