2013-09-15 - 163805 - d16 Aveo [PDF]

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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Inst... Page 1 of 13



2008 Chevrolet Aveo : Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Instructions - On Vehicle > Transmission Replacement



Transmission Replacement TRANSMISSION REPLACEMENT Tools Required J 28467-B (Image 1) Removal Procedure



CAUTION Caution: Refer to Battery Disconnect Caution in the Preface section.



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1.



Install the J 28467-B (Image 1) .



2.



Remove the battery and battery tray.



3.



Remove the shift linkage assembly. Refer to Shift Control Linkage Replacement.



4.



Remove the drive axle shaft. Refer to Front Drive Axle Inner Shaft Replacement.



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Inst... Page 2 of 13



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5.



Disconnect the backup lamp switch electrical connector.



6.



Disconnect the speedometer speed sensor electrical connector.



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7.



Remove the clutch release cylinder retaining bolts and the clutch release cylinder.



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Inst... Page 3 of 13



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8.



Remove the damping block connection nut and bolt.



9.



Remove the 3 rear mounting bracket bolts.



10.



Remove the rear mounting bracket from the transaxle.



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11.



Remove the 2 rear damping block retaining bolts.



12.



Remove the rear damping block from the front cross member.



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Inst... Page 4 of 13



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13.



Remove the 2 cage retaining bolts.



14.



Remove the 3 transaxle upper mounting bracket bolts.



15.



Remove the upper mounting bracket and cage.



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16.



Remove the starter. Refer to Starter Replacement (Refer To List 1).



NOTE



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Inst... Page 5 of 13



Important: Removing the coolant tube bolts allows enough movement in the tube to access the upper engine to transmission bolts.



17.



Remove the coolant tube bolts (1).



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18.



Remove the 3 transaxle upper retaining bolts.



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19.



Support the transaxle with a transaxle support jack.



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Inst... Page 6 of 13



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20.



Remove the 7 transaxle lower retaining bolts.



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NOTE Important: Rest the transaxle only in an upright position



21.



Remove the transaxle.



22.



Slide the transaxle sideways away from the engine block.



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Inst... Page 7 of 13



23.



Lower the transaxle.



Installation Procedure



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1.



Support the transaxle with a transaxle support jack.



2.



Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block.



NOTE Notice: Refer to Fastener Notice (Refer To List 2) in the Preface section.



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Inst... Page 8 of 13



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3.



Install the 7 transaxle lower retaining bolts. Tighten ■



Tighten the transaxle lower retaining bolts (1) to 73 N·m (54 lb ft).



■



Tighten the transaxle lower retaining bolts (2) to 31 N·m (23 lb ft).



■



Tighten the transaxle lower retaining bolt (3) to 21 N·m (15 lb ft).



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4.



Install the three transaxle upper retaining bolts. Tighten Tighten the transaxle upper retaining bolts to 73 N·m (54 lb ft).



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Inst... Page 9 of 13



Click to Enlarge



5.



Install the coolant tube bolts (1).



6.



Install the starter. Refer to Starter Replacement (Refer To List 1).



Click to Enlarge



7.



Install the cage retaining bolt and cage.



8.



Install the three transaxle upper mounting bracket bolts and bracket. Tighten



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair I... Page 10 of 13



Tighten the transaxle upper mounting bracket bolts to 60 N·m (44 lb ft).



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9.



Install the 2 rear damping block retaining bolts. Tighten Tighten the rear damping block retaining bolts to 55 N·m (41 lb ft).



10.



Install the rear damping block from the front cross member.



Click to Enlarge



11.



Install the 3 rear mounting bracket bolts and the bracket. Tighten Tighten the rear mounting bracket bolts to 80 N·m (59 lb ft).



12.



Install the damping block connection nut and bolt. Tighten



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair I... Page 11 of 13



Tighten the damping block connection nut and bolt to 80 N·m (59 lb ft).



Click to Enlarge



13.



Install the clutch release cylinder retaining bolts and the clutch release cylinder. Tighten Tighten the clutch release cylinder retaining bolts to 20 N·m (15 lb ft).



Click to Enlarge



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair I... Page 12 of 13



14.



Connect the speedometer speed sensor electrical connector.



15.



Connect the backup lamp switch electrical connector.



Click to Enlarge



16.



Remove the J 28467-B (Image 1) .



17.



Install the drive axle shaft. Refer to Front Drive Axle Inner Shaft Replacement.



18.



Install the shift linkage assembly. Refer to Shift Control Linkage Replacement.



19.



Install the battery and battery tray.



20.



Inspect the fluid level. Refer to Transmission Fluid Level Inspection.



REFERED IMAGES LIST: REFER TO LIST:



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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair I... Page 13 of 13



(Image 1) J 28467-B



List 1 ■



Engine / Engine Electrical / Repair Instructions / Starter Replacement (1.4L/1.5L SOHC And 1.4L/1.6L DOHC)



■



Engine / Engine Electrical / Repair Instructions / Starter Replacement (1.2L SOHC)



List 2 ■



Preface / Cautions And Notices / Introduction / Fastener Notice



■



Unsorted / Fastener Notice



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