2002 CHEVROLET AVEO brake

Fig. 230: 1st & Reverse Brake Piston
Courtesy of GENERAL MOTORS CORP.
34. Install the 1st and reverse brake piston to the transaxle case.
IMPORTANT: Do not damage the O-rings of the 1st and reverse brake piston.

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Fig. 233: DT 46455, DT 46457, Snap Ring Of 1st & Reverse Brake
Courtesy of GENERAL MOTORS CORP.
37. Usin
g DT 46457 (2) and DT 46455 (1), install the snap ring. See Special Tools.
IMPORTANT: Verify that the snap ring is installed correctly in the groove of the
transaxle case.

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Fig. 234: Measuring The 1st & Reverse Brake Piston Stroke Using A Dial Indicator
Courtesy of GENERAL MOTORS CORP.
38. Using a dial indicator, measure the 1st and reverse brake piston stroke while applying and releasing 392-
785 kPa (57-114 psi) of compressed air.
IMPORTANT: If the piston stroke is non-standard, inspect the discs, the plates and the
flange. The piston stroke is 0.6-1.3 mm (0.024-0.051 in).

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Fig. 255: Measuring The Free Length Of 2nd Brake Piston Return Spring Using Vernier Calipers
Courtesy of GENERAL MOTORS CORP.
64. Using vernier calipers, measure the free length of the 2nd brake piston return spring together with the
spring seat.
Specification: The standard free len
gth is 15.85 mm (0.6240 in).

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Fig. 256: Disc
Courtesy of GENERAL MOTORS CORP.
65. If the sliding surface of the disc, the plate and the flange of 2nd brake are worn or burnt, replace the parts.
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.

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Fig. 257: Flange, Discs & Plates
Courtesy of GENERAL MOTORS CORP.
66. Install the flange, 2 discs and 2 plates in order: 2-1-3-1-3, where (1)=Disc, (2)=Flange, and (3)=Plate.
67. Install the 2nd brake return spring.
IMPORTANT: Install the snap ring in the groove of the transaxle case correctly.

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Fig. 258: O-Rings & 2nd Brake Piston
Courtesy of GENERAL MOTORS CORP.
68. Coat 2 new O-rings (1) with ATF and install the O-rings to the 2nd brake piston.

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Fig. 259: 2nd Brake Piston & 2nd Brake Clutch Cylinder
Courtesy of GENERAL MOTORS CORP.
69. Install the 2nd brake piston into the 2nd brake clutch c
ylinder.
IMPORTANT: Do not damage the O-rings.

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