2002 CHEVROLET AVEO brake

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

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 206: Measuring Free Length Of O/D Brake Piston Return Spring Using The Vernier Calipers
Courtesy of GENERAL MOTORS CORP.
4. Using the vernier calipers, measure the free length of the overdrive (O/D) brake piston return spring
together with the spring seat.
Specification: The standard free len
gth is 18.99 mm (0.7476 in).

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 207: O-Rings & O/D Brake Piston
Courtesy of GENERAL MOTORS CORP.
5. Coat 2 new O-rings (1) with automatic transaxle fluid (ATF). Install the O-rings to the O/D brake piston.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:24 PMPage 220 © 2005 Mitchell Repair Information Company, LLC.

Fig. 208: O/D Brake Piston & ATF
Courtesy of GENERAL MOTORS CORP.
6. Coat the O/D brake piston with ATF. Install the piston to the transaxle rear cover.
IMPORTANT: Do not damage the O-rings of the O/D brake piston.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:24 PMPage 221 © 2005 Mitchell Repair Information Company, LLC.

Fig. 209: Removing Snap Ring Using A Driver, DT 46451 & DT46454
Courtesy of GENERAL MOTORS CORP.
7. Using DT 46451 (1), DT 46454 (2) and a driver, install the O/D brake return spring and snap ring to the
transaxle rear cover. See Special Tools
.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:24 PMPage 222 © 2005 Mitchell Repair Information Company, LLC.

Fig. 227: Measuring The Free Length Of 1st & Reverse Brake Piston Return Spring Using The
Vernier Calipers
Courtesy of GENERAL MOTORS CORP.
31. Using the vernier calipers, measure the free length of the 1st and reverse brake piston return spring
together with the spring seat.
Specification: The standard free len
gth is 18.053 mm (0.71075 in).

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:24 PMPage 240 © 2005 Mitchell Repair Information Company, LLC.

Fig. 228: Sliding Surface Of Disc
Courtesy of GENERAL MOTORS CORP.
32. Inspect the sliding surface of the disc, the plate and the flange of the 1st and reverse brake for wear or
burn. Replace the parts, if necessary.
IMPORTANT:If the lining of the disc is peeling off or discolored, or even if a part
of the groove is defaced, replace all discs.
Before assembling the new discs, soak the discs in ATF for at least
15 minutes.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:24 PMPage 241 © 2005 Mitchell Repair Information Company, LLC.

Fig. 229: O-Rings & 1st & Reverse Brake Piston
Courtesy of GENERAL MOTORS CORP.
33. Coat 2 new O-rin
gs (1) with ATF, install the O-rings to the 1st and reverse piston.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:24 PMPage 242 © 2005 Mitchell Repair Information Company, LLC.