2002 CHEVROLET AVEO differential

Fig. 410: Differential Side Gears, 2 Differential Pinion Thrust Washers, And 2 Differential Side
Gear Thrust Washers
Courtesy of GENERAL MOTORS CORP.
6. Install the 2 side gears with 2 thrust washers, 2 pinion gears, and 2 pinion thrust washers into the
differential case.
7. Coat the pinion shaft with ATF.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:32 PMPage 424 © 2005 Mitchell Repair Information Company, LLC.

Fig. 411: Differential Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
8. Install the pinion shaft so as to ali
gn the lock pin holes on the pinion shaft and differential case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:32 PMPage 425 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of GENERAL MOTORS CORP.
11. Using a hammer and punch, drive in the pin through the case and holes in the pinion shaft.
Fig. 414: Staking The Differential Case Using A Hammer & Chisel

Courtesy of GENERAL MOTORS CORP.
12. Usin
g a hammer and chisel, stake the differential case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:32 PMPage 428 © 2005 Mitchell Repair Information Company, LLC.

Fig. 415: Tapered Roller Bearing & Differential Case
Courtesy of GENERAL MOTORS CORP.
13. Using a press, install the tapered roller bearing into the differential case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:32 PMPage 429 © 2005 Mitchell Repair Information Company, LLC.

Fig. 416: FIPG, Tapered Roller Bearing & Differential Case
Courtesy of GENERAL MOTORS CORP.
14. Using a press, install the tapered roller bearing into the differential case.
15. Remove any formed in place gasket (FIPG) material. Do not get oil on the contacting surfaces of the
transaxle housin
g or transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:32 PMPage 430 © 2005 Mitchell Repair Information Company, LLC.

Fig. 417: Differential & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
16. Install the differential to the transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:32 PMPage 431 © 2005 Mitchell Repair Information Company, LLC.

Fig. 419: Turning The Differential Gear Assembly
Courtesy of GENERAL MOTORS CORP.
19. Using the DT 46461 , turn the differential gear assembly right and left 2-3 times to allow the bearing to
settle. See Special Tools
.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:32 PMPage 433 © 2005 Mitchell Repair Information Company, LLC.

Fig. 420: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
Courtesy of GENERAL MOTORS CORP.
20. Using the DT 46461 and a small torque wrench, measure the preload of the differential gear. See Special
Tools.
Specifications:
New bearing preload is 0.78-1.37 N.m (6.9-12.2 lb in).
Used bearing preload is 0.39-0.69 N.m (3.5-6.1 lb in).
21. Re-select the transaxle case side adjusting the shim according to the shim thickness table. Refer to
Transmission General Specifications
.
IMPORTANT: If the preload is not within specifications, remove the differential from the
transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:32 PMPage 434 © 2005 Mitchell Repair Information Company, LLC.