2002 CHEVROLET AVEO differential

2006 TRANSMISSION
Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
Application
Specification
MetricEnglish
Check Valve Spring Bolts6.5 N.m57 lb in
Control Cable Adjusting Nut8 N.m71 lb in
Damping Block Connection Nut and Bolt80 N.m59 lb ft
Differential Case-to-Differential Ring Gear Bolt102 N.m75 lb ft
Drain Plug17 N.m13 lb ft
Fluid Cooler Inlet Pipe Bolt9 N.m80 lb in
Fluid Cooler Inlet Pipe Fitting Nut35 N.m26 lb ft
Fluid Cooler Rear Outlet Pipe Clip Bolt9 N.m80 lb in
Fluid Cooler Rear Outlet Pipe Fitting Nut35 N.m26 lb ft
Front Outlet Pipe Clip Bolt9 N.m80 lb in
Front Outlet Pipe Union Bolt35 N.m26 lb ft
Input Speed Sensor Retaining Bolt5.4 N.m48 lb in
Manual Detent Spring Bolt9.8 N.m87 lb in
Manual Valve Lever Shaft Nut12 N.m106 lb in
Lower Transaxle-to-Engine Retaining Bolts73 N.m54 lb ft
Lower Transaxle-to-Engine Retaining Bolts31 N.m23 lb ft
Lower Transaxle-to-Engine Retaining Bolts21 N.m15 lb ft
Oil Pan Bolts7 N.m62 lb in
Oil Pump Bolts25 N.m18 lb ft
Oil Reservoir Lock Plate Bolts5.4 N.m48 lb in
Oil Strainer Bolts9.8 N.m87 lb in
Output Speed Sensor Retaining Bolt7.4 N.m65 lb in
Park/Neutral Position Switch Bolts5.4 N.m48 lb in
Parking Lock Pawl Bracket Bolts7.4 N.m65 lb in
Planetary Ring Gear Nut-Maximum29 N.m22 lb ft
Planetary Ring Gear Nut-Standard9.8 N.m87 lb in
Rear Mounting Bracket Bolts60 N.m44 lb ft
Screw Plugs7.4 N.m65 lb in
Shift Control Lever Assembly Mounting Bolts8 N.m71 lb in
Shift Solenoid Valve Bolts11 N.m97 lb in

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Thursday, July 16, 2009 1:17:42 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.

Flange Thickness
Accumulator Spring
TRANSMISSION GEAR RATIO
Transmission Gear Ratio
Mark G2.17 mm0.0854 in
Mark H2.20 mm0.0866 in
Mark K2.25 mm0.0886 in
Mark L2.30 mm0.0906 in
Mark M2.35 mm0.0925 in
Mark N2.40 mm0.0945 in
Mark P2.45 mm0.0965 in
Mark Q2.50 mm0.0984 in
Mark R2.55 mm0.1004 in
Mark S2.60 mm0.1024 in
Mark U2.65 mm0.1043 in
Mark W2.70 mm0.1063 in
MarkPiston StrokeThickness
MetricEnglishMetricEnglish
00.738-0.949 mm0.02905-0.03736 in3.0 mm0.118 in
10.950-1.149 mm0.03740-0.04524 in3.2 mm0.126 in
21.150-1.349 mm0.04528-0.05311 in3.4 mm0.134 in
31.350-1.549 mm0.05315-0.06098 in3.6 mm0.142 in
01.550-1.702 mm0.06102-0.06701 in3.8 mm0.150 in
Spring
Free length Outer Diameter
ColorMetricEnglish
O/D and 2nd brake47.13 mm/16.0 mm1.8555 in/0.630 inPink
Forward Clutch57.90 mm/17.2 mm2.2795 in/0.677 in-
Direct Clutch57.20 mm/17.5 mm2.2520 in/0.689 inGreen
GearRatio
First2.875
Second1.568
Third1.000
Fourth0.697
Reverse2.300
Counter1.019
Differential 1.4L/1.5L/1.2L SOHC3.750
Differential 1.4L DOHC4.052

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:16 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.

Fig. 22: Case And Associated Parts (2 of 2)
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 22
CalloutComponent Name
1Oil Seal
2Transaxle Housing
3Oil Reservoir Plate
4Transaxle Oil Apply Pipe
5Spring
6Check Valve Pipe Clamp
7Apply Gasket
8Brake Drum Gasket
9Differential Gear Oil Apply Pipe

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 22 © 2005 Mitchell Repair Information Company, LLC.

Fig. 24: Differential And Oil Pump Component View
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 24
CalloutComponent Name
1Side Bearing Outer Race
2Shim
3Outer Tapered Roller Bearing Race
4Counter Driven Gear
5Oil Seal
6Transaxle Case Plate
7Apply Gasket
8Counter Driven Gear
9Direct Clutch Hub
10Thrust Bearing Race
11Direct Clutch Assembly
12Thrust Needle Roller Bearing
13Differential Case
14Oil Pump

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 26 © 2005 Mitchell Repair Information Company, LLC.

Fig. 31: Differential Case Component View
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 42
6Modulator
Valve24 mm0.945 in5 mm0.197 in3.2 mm0.126 in
7
Low
Modulator
Valve
24 mm0.945 in5 mm0.197 in3.2 mm0.126 in
CalloutComponent Name

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

DIAGNOSTIC INFORMATION AND PROCEDURES
DIAGNOSTIC CODE INDEX
DIAGNOSTIC CODE INDEX
1Differential Pinion Thrust Washer
2Differential Pinion Gear
3Differential Side Gear Thrust Washer
4Differential Side Gear
5Pin
6Differential Pinion Shaft
7Oil Seal
8Side Bearing Outer Race
9Tapered Roller Bearing
10Differential Case
11Differential Ring Gear
12Tapered Roller Bearing
13Side Bearing Outer Race
14Shim
15Oil Seal
DTCDescription
DTC P0562 (Non-Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0562 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0563 (Non-Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0563 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0601 or P1790 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0601 or P1790 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0604 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0604 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0705 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0705 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0706 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0706 (Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0711 DTC P0711Transmission Fluid
Temperature (TFT) Sensor Circuit
Performance
DTC P0712 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0712 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0713 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0713 (European and N. American Emissions) ** MULTIPLE VALUES **

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 41 © 2005 Mitchell Repair Information Company, LLC.

Fig. 148: Transaxle Housing
Courtesy of GENERAL MOTORS CORP.
36. Remove the 16 bolts and tap on the circumference of the transaxle housing with a plastic hammer to
remove the transaxle housing from the transaxle case.
IMPORTANT: Be careful not to drop the differential gear assembly when the transaxle
housing is removed.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:22 PMPage 161 © 2005 Mitchell Repair Information Company, LLC.

Fig. 151: Differential Gear Assembly & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
39. Remove the differential
gear assembly from the transaxle case.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:22 PMPage 164 © 2005 Mitchell Repair Information Company, LLC.