2002 CHEVROLET AVEO brake

Fig. 62: TCM Electrical Connector
Courtesy of GENERAL MOTORS CORP.
2. Locate the transmission control module (TCM) electrical connector next to the brake pedal assembly.
3. Disconnect the transmission control module (TCM) electrical connector.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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5. Check the fluid level and add fluid until the dipstick indicates a safe level.
TRANSMISSION DISASSEMBLE
Tools Required
DT 46451 (DW240-020) Brake/Clutch Spring Compressor. See Special Tools.
DT 46454 (DW240-050) Overdrive Brake Adapter. See Special Tools.
DT 46455 (DW240-060-01) Brake Spring Compressor Bolt/Nut. See Special Tools.
DT 46457 (DW240-070) 1st and Reverse Brake Adapter. See Special Tools.
DT 46463 (DW240-150) Transaxle Case Side Bearing Outer Race Adapter. See Special Tools.
DT 46465 (DW240-170) Adapter Handle. See Special Tools.
DT 46453 (DW260-021) Automatic Transaxle Overhaul Fixture. See Special Tools.
DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket. See Special Tools.
Disassembly Procedure
IMPORTANT: The correct fluid level must be between the HOT MIN (2) and the HOT MAX
(1) notches on the dipstick.

2006 Chevrolet Aveo
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Fig. 138: Brake Drum Gasket
Courtesy of GENERAL MOTORS CORP.
24. Remove the brake drum
gasket.

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2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 144: Applying Compressed Air To Oil Hole & Removing O/D & 2nd Brake Clutch
Accumulator Piston & Spring.
Courtesy of GENERAL MOTORS CORP.
32. Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the over drive (O/D) and 2nd
brake clutch accumulator piston and spring.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice .
IMPORTANT:
Air pressure may cause the pistons to jump out. When removing the
piston, hold it in place with your hand using a waste cloth.
Take care not to 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. 145: O-Rings, O/D & 2nd Brake Accumulator Piston
Courtesy of GENERAL MOTORS CORP.
33. Remove the 2 O-rin
gs (1) from the O/D and 2nd brake accumulator piston.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 159: O/D Brake Flange, Discs & Plates
Courtesy of GENERAL MOTORS CORP.
47. Remove 2nd coast and O/D brake flan
ge (1), 2 discs (2), and 2 plates (3) from the transaxle case.

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Fig. 169: DT 46455 & DT 46458
Courtesy of GENERAL MOTORS CORP.
58. Using the DT 46455 (1) and DT 46458 (2), remove the 2 snap rings, 2nd brake piston, and 2nd brake
piston return sprin
g. See Special Tools.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice .

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 170: Applying Compressed Air To 2nd Brake To Remove 2nd Brake Piston From The 2nd
Brake Clutch Cylinder
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice .
IMPORTANT:
Air pressure may cause the pistons to jump out. When removing the
piston, hold it in place with your hand using a waste cloth.
Take care not to splash ATF when air-blowing.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:22 PMPage 183 © 2005 Mitchell Repair Information Company, LLC.