2002 CHEVROLET AVEO brake

Fig. 260: 2nd Brake Clutch Cylinder & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
70. Install the 2nd brake clutch c
ylinder to the transaxle case.

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Fig. 261: DT 46455 & DT 46458
Courtesy of GENERAL MOTORS CORP.
71. Using DT 46455 (1) and DT 46458 (2), compress the 2nd brake piston return spring. See Special Tools
.
72. Using the screwdriver, install the snap ring.
IMPORTANT: Install the snap ring in the groove of the transaxle case correctly.

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Fig. 273: Sliding Surface Of Disc
Courtesy of GENERAL MOTORS CORP.
84. If the sliding surface of the disc, the plate and the flange of 2nd coast and O/D brake are worn or burnt,
replace the components.
IMPORTANT:If the lining of the disc is peeling off or discolored, or even if the part
of the printed mark is defaced, replace all discs.
Before assembling new discs, soak the discs in ATF for at least 15
minutes.

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Fig. 275: O/D Brake Flange, Discs & Plates
Courtesy of GENERAL MOTORS CORP.
86. Install the flange, 2 discs and 2 plates to the transaxle case in the following order: 3-2-3-2-1, where (3)
=Plate, (2)=-Disc, and (1)=Flange.
87. Clean the connected part the transaxle case and the transaxle rear cover.

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Fig. 276: Measuring The Distance Between 2nd Coast & O/D Brake Flange Using Vernier Calipers
Courtesy of GENERAL MOTORS CORP.
88. Place a straight edge on the transaxle case and measure the distance between the 2nd coast and the O/D
brake flange and the straight edge using vernier calipers (a).

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Fig. 277: Measuring The Distance Between Transaxle Rear Cover & Straight Edge Using Vernier
Calipers
Courtesy of GENERAL MOTORS CORP.
89. Place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover
and the straight edge using vernier calipers (a).
90. Calculate the piston stroke value using the following formula. Select and install a flange which satisfies
the piston stroke value.

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Fig. 298: Brake Drum Gasket
Courtesy of GENERAL MOTORS CORP.
116. Coat a new brake drum
gasket with ATF and install the gasket to the transaxle case.

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DT 46451 (DW240-020) Brake Clutch Spring Compressor. See Special Tools.
DT 46453 (DW240-040) Direct Clutch Adapter. See Special Tools.
Fig. 329: Using A Dial Indicator Measure The Direct Clutch Piston Stroke While Applying
Compressed Air
Courtesy of GENERAL MOTORS CORP.
1. Install the direct clutch and thrust needle roller bearing on the oil pump.
2. Using a dial indicator, measure the direct clutch piston stroke while applying and releasing 392 kPa (57
psi) of compressed air.
If the stroke is non-standard, inspect the discs, the plates, and the flan
ge.
NOTE: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice in
Cautions and Notices.

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