2002 CHEVROLET AVEO differential

Fig. 283: Differential Gear Assembly & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
97. Install the differential
gear assembly to the transaxle case.

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Fig. 394: Tapered Roller Bearing & Transaxle Housing Side
Courtesy of GENERAL MOTORS CORP.
6. Using a press, install a new tapered roller bearing of the transaxle housing side.
DIFFERENTIAL ASSEMBLY DISASSEMBLE
Tools Required
DT 46463 (DW240-150) Transaxle Case Side Bearing Outer Race Adapter. See Special Tools.
DT 46465 (DW240-170) Adapter Handle. See Special Tools.

2006 Chevrolet Aveo
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Fig. 395: Matchmarks, Ring Gear & Differential Case
Courtesy of GENERAL MOTORS CORP.
1. Place the matchmarks (1) on the ring gear and differential case.

2006 Chevrolet Aveo
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Fig. 396: Differential Assembly & Bolts
Courtesy of GENERAL MOTORS CORP.
2. Remove the 8 bolts.

2006 Chevrolet Aveo
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Fig. 401: Differential Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
7. Remove the differential pinion shaft from the case.

2006 Chevrolet Aveo
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Fig. 402: Differential Side Gears, 2 Differential Pinion Thrust Washers, And 2 Differential Side
Gear Thrust Washers
Courtesy of GENERAL MOTORS CORP.
8. Remove the 2 differential pinion gears, 2 differential side gears, 2 differential pinion thrust washers, and
2 differential side gear thrust washers.

2006 Chevrolet Aveo
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Fig. 406: Removing Transaxle Case Side Bearing Outer Race & Shim Using DT 46463 & DT 46465
Courtesy of GENERAL MOTORS CORP.
12. Using the DT 46463 (2) and the DT 46465 (1), remove the transaxle case side bearing outer race and
shim. See Special Tools
.
DIFFERENTIAL ASSEMBLY ASSEMBLE
Tools Required
DT 46462 (DW240-140) Transaxle Case Side Bearing Outer Race Adapter. See Special Tools.
DT 46465 (DW240-170) Adapter Handle. See Special Tools.
DT 46461 (DW240-130) Differential Preload Adapter. See Special Tools.
DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer. See Special Tools.
DT 47521 (DW260-031-02) Transaxle Case Oil Seal Installer. See Special Tools.

2006 Chevrolet Aveo
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Fig. 409: Differential Side Gear Thrust Washers & Differential Side Gears
Courtesy of GENERAL MOTORS CORP.
4. Coat the thrust washers, side gears, pinion gears, and pinion thrust washers with automatic transmission
fluid (ATF).
5. Install the 2 differential side
gear thrust washers to 2 differential side gears.

2006 Chevrolet Aveo
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Thursday, July 16, 2009 1:17:31 PMPage 423 © 2005 Mitchell Repair Information Company, LLC.