Service Manual2011 Aveo Counter Driven Gear

Aveo

Counter Driven Gear

Outer Tapered Roller Bearing Race
Tapered Roller Bearing
Counter Drive Pinion
Counter Driven Gear
Tapered Roller Bearing
Outer Tapered Roller Bearing Race

Tools Required

DW240-160 Transaxle Case Outer Tapered Roller Bearing Race Adapter

DW240-170 Adapter Handle

Disassembly Procedure

Using a suitable puller, remove the tapered roller bearing from the transaxle case side.

Using a press, remove the counter driven gear.

Using a suitable puller, remove the tapered roller bearing.
Using a suitable puller, remove the outer tapered roller bearing race and shim from the transaxle case.
Using a suitable puller, remove the outer tapered roller bearing race from the transaxle housing.

Assembly Procedure

Install a new outer tapered roller bearing race into the transaxle housing.

Notice : Press-fit the outer tapered roller bearing race until it contacts the transaxle housing.

Install the shim to the transaxle case.

First install a shim of the same thickness as before.

Using transaxle case outer tapered roller bearing race adapter DW240-160 and adapter handle DW240-170, press in a new outer tapered roller bearing race into the transaxle case.

Notice : Press-fit the shim until it contacts the transaxle case.

Using a press, install the counter driven gear.

Using a press, install a new tapered roller bearing of the transaxle case side.

Using a press, install a new tapered roller bearing of .the transaxle housing side.

Valve Body

Manual Valve
Upper Valve Body
Valve Body Plate
No1. Solenoid Valve
O-Ring
No2. Solenoid Valve
O-Ring
Pressure Control Solenoid Valve
Lower Valve Body
Timing Solenoid Valve
O-Ring
Lock-up Solenoid Valve

Cover

Disassembly Procedure

Write down the relative position of the primary regulator valve sleeve, plug and pin.

Notice : Because the line pressure is changed by the position of the pin and groove in the sleeve end, be sure to check the position.

Remove the manual valve.

Remove the 5 bolts and 5 shift solenoid valves.

Remove the 15 bolts.

Remove the cover, 2 gaskets and plate.

Remove the spring, check valve and check ball.
Remove the bolt, spring seat, spring and ball.
Turn over the valve body.

Remove the 2 bolts from the valve body.

Remove the upper valve body from the lower valve body with plate.

Remove the valve body plate from the lower valve body.

Notice : Be careful that the check balls do not fall out.

Assembly Procedure

Install the valve body plate to the lower valve body.

Install the upper valve body to the lower valve body with plate.

Install the 2 bolts to the valve body.

Tighten

Tighten the bolts to 11 N•m (97 lb-in).

Bolt A: 49 mm (1.93 in.)

Bolt B: 36 mm (1.42 in.)

Turn the valve body.

Install the check valve, spring and check ball.
Install the ball, spring, spring seat and bolt.

Tighten

Tighten the bolts to 6.5 N•m (57 lb-in).

Install the 2 gaskets, plate and lower valve body cover.

First, tighten the bolts indicated by arrows temporarily and then tighten the other bolts temporarily.
Tighten all the bolts completely.

Tighten

Tighten the bolts to 11 N•m (97 lb-in).

Bolt length:

Bolt A: 49 mm (1.93 in.)

Bolt B: 20 mm (0.79 in.)

Bolt C: 60 mm (2.36 in.)

Install the 5 shift solenoid valves with the 6 bolts.

Tighten

Tighten the bolts to 11 N•m (97 lb-in).

Bolt length:

Bolt A: 49 mm (1.93 in.)

Bolt B: 20 mm (0.79 in.)

Install the manual valve.

Make sure that the primary regulator valve is positioned in the same place where it was removed.

Upper Valve Body

Plug
Key
Secondary Regulator Valve
Spring
No.2 Check Valve
Key
Ball
No.1 Check Valve
Reverse Control Valve
Spring
Key
Plug
Spring
3-4 Shift Valve
Spring
O-ring
Reverse Clutch Accumulator Piston
O-ring
Plunger
3-4 Shift Timing Valve
Spring
O-ring
2nd Brake Accumulator Piston
O-ring
Spring
Upper Valve Body Cover

Upper Valve Body Spring

During reassembly, please refer to the spring specifications below to help you do discriminate between the different springs.

Mark	Name (Color)	Free length/Outer diameter mm (in.)	Total number of coils
A	3-4 shift timing valve (Pink)	28.41 (1.1185) / 6.4 (0.252)	10.49
B	2nd brake accumulator piston,(None) Inner	45.90 (1.8071) / 10.5 (0.413)	16.9
C	2nd brake accumulator piston,(White) Outer	69.00 (2.7165) / 16.0 (0.630)	15.1
D	Reverse clutch accumulator piston (None)	65.40(2.5748) / 17.0 (0.669)	13.7
E	3-4 shift valve (Red)	25.50 (1.0039) / 9.73 (0.3831)	7.75
F	Secondary regulator valve (White)	34.56 (1.3606) / 8.8 (0.346)	12.27
G	Reverse control valve (None)	25.58 (1.0071) / 8.64 (0.3402)	8.75
H	Lock up control valve (Yellow)	20.87 (0.8217) / 5.55 (0.2185)	11.15

Upper Valve Body Key

Mark	Retainer	Height/Width/Thickness mm (in.)
A	Check valve	11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)
B	Secondary regulator valve	16.0 (0.630) / 5.0 (0.197) / 3.2 (0.126)
C	Lock up control valve	16.0 (0.630) / 5.0 (0.197) / 3.2 (0.126)
D	Reverse control valve	11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)

Upper Valve Body Check Ball

Check ball mm(in).

5.535 (0.21791)

Lower Valve Body

Key
Spring
4-3 Shift Timing Valve
Key
Plug
2-3 Shift Valve
Spring
Key
Plug
1-2 Shift Valve
Spring
Key
Sleeve
Plunger
Spring
Primary Regulator Valve
Key
Sleeve
Plunger
Spring
Lock-up Relay Valve
Key
Spring
Solenoid Modulator Valve
Solenoid Oil Strainer
Lower Modulator Valve
Spring
Key

Lower Valve Body Spring

Mark	Name (Color)	Free length/Outer diameter mm (in.)	Total number of coils
A	4-3 shift timing valve No.1 (None)	33.95 (1.3366) / 8.2 (0.323)	12.5
B	Low modulator valve (None)	30.43 (1.1980) / 7.75 (0.3051)	12.72
C	2-3 shift valve (Red)	25.50 (1.0039) / 9.73 (8.1694)	7.75
D	1-2 shift valve (Red)	25.50 (1.0039) / 9.73 (8.1694)	7.75
E	Primary regulator valve (None)	50.53 (1.9894) / 13.6 (0.535)	11.07
F	Lock up relay valve (Red)	23.42 (0.9221) / 5.86 (0.2307)	12.25
G	Solenoid modulator valve (Yellow)	32.13 (1.2650) / 8.0 (0.315)	15.75

Lower Valve Body Key

Mark	Retainer	Height/Width/Thickness mm (in.)
A	4-3 shift timing valve No.1	36.0 (1.417) / 5.0 (0.197) / 3.2 (0.126)
B	Low modulator valve	24.0 (0.945) / 5.0 (0.197) / 3.2 (0.126)
C	2-3 shift valve	10.0 (0.394) / 5.0 (0.197) / 3.2 (0.126)
D	1-2 shift valve	10.0 (0.394) / 5.0 (0.197) / 3.2 (0.126)
E	Primary regulator valve	9.8 (0.386) / 5.2 (0.205) / 3.2 (0.126)
F	Lock up relay valve	16.0 (0.630) / 5.0 (0.197) / 3.2 (0.126)
G	Solenoid modulator valve	24.0 (0.945) / 5.0 (0.197) / 3.2 (0.126)

Differential Case

Oil Seal
Differential Side Gear Thrust Washer
Differential Pinion Thrust Washer
Differential Pinion Gear
Differential Pinion Shaft
Differential Side Gear
Pin
Side Bearing Outer Race
Tapered Roller Bearing
Differential Case
Differential Ring Gear
Tapered Roller Bearing
Side Bearing Outer Race
Shim
Oil Seal

Tools Required

DW260-031-01 Transaxle Housing Oil Seal Installer

DW260-031-02 Transaxle Case Oil Seal Installer

DW240-150 Transaxle Case Side Bearing Outer Race Adapter

DW240-140 Transaxle Housing Side Bearing Outer Race Adapter

DW240-170 Adapter Handle

Disassembly Procedure

Place the matchmarks on the ring gear and differential case.

Remove the 8 bolts.

Using a plastic hammer, tap on the ring gear to remove it from the case.

Using a suitable puller, remove the tapered roller bearing of transaxle housing side.

Using a suitable puller, remove the tapered roller bearing of transaxle case side.

Using a pin punch and hammer, drive out the pin from the ring gear side.

Remove the differential pinion shaft from the case.

Remove the 2 differential pinion gears, 2 differential side gears, 2 differential pinion thrust washers and 2 differential side gear thrust washers.

Using a driver, remove the oil seal from the transaxle housing.

Notice : Be careful not to damage the transaxle housing when removing the oil seal using a driver.

Using a suitable puller, remove the side bearing outer race of transaxle housing.

Using a driver, remove the oil seal of transaxle case.

Notice : Be careful not to damage the transaxle case when removing the oil seal using a driver.

Using transaxle case side bearing outer race adapter DW240-150 and adapter handle DW240-170, remove the transaxle case side bearing outer race and shim.

Assembly Procedure

Using transaxle housing side bearing outer race adapter DW240-140 and adapter handle DW240-170, install a new side bearing outer race into the transaxle housing.

Install the shim to the transaxle case.

Notice : First install a shim of the same thickness as before.

Install a new side bearing outer race into the transaxle case.

Coat the thrust washers, side gears, pinion gears and pinion thrust washers with ATF.
Install the 2 differential side gear thrust washers to 2 differential side gears.

Install the 2 side gears with 2 thrust washers, 2 pinion gears and 2 pinion thrust washers into the differential case.
Coat the pinion shaft with ATF.

Install the pinion shaft so as to align the lock pin holes on the pinion shaft and differential case.

Measure the side gear backlash while holding 1 pinion gear toward the case.

Standard backlash:

0.05 – 0.20 mm (0.0020-0.0079 in.)

If the backlash is out of specification, install the correct thrust washer to the side gear.

Referring to the table below, select thrust washers which will ensure that the backlash is within the specification.

Try to select washers of the same size for both sides.

Thrust washer thickness : mm (in.)

Thickness	Thickness
0.95 (0.0374)	1.10 (0.0433)
1.00 (0.0394)	1.15 (0.0453)
1.05 (0.0413)	1.20 (0.0472)

If the backlash is not within the specification, install a thrust washer of a different thickness.

Using a hammer and punch, drive in the pin through the case and hole in the pinion shaft.

Using a hammer and chisel, stake the differential case.

Using a press, install the tapered roller bearing into the differential case.

Using a press, install the tapered roller bearing into the differential case.
Remove any formed in place gasket (FIPG) material and be careful not to get oil on the contacting surfaces of the transaxle housing or transaxle case.

Install the differential to the transaxle case.

Install the transaxle housing and 16 bolts of the transaxle housing temporarily.
Tighten 8 or 9 bolts out of 16 bolts of the transaxle housing completely.

Tighten

Tighten the bolts to 29 N•m (22 lb-ft).

Using differential preload adapter DW240-130, turn the differential gear assembly right and left 2 or 3 times to allow the bearing settle.

Using differential preload adapter DW240-130 and small torque wrench, measure the preload of the differential gear.

Preload:

New bearing: 0.78-1.37 N.m (6.9-12.2 lb -in)

Used bearing : 0.39-0.69 N.m (3.5 – 6.1 lb-in)

If the preload is not within the specification, remove the differential from the transaxle case. Re-select the transaxle case side adjusting shim according to the following table.

Adjusting shim thickness :mm (in.)

Mark	Thickness	Mark	Thickness
A	1.80 (0.0709)	N	2.26 (0.0890)
B	1.85 (0.0728)	P	2.29 (0.0902)
C	1.90 (0.0748)	Q	2.32 (0.0913)
D	1.95 (0.0768)	R	2.35 (0.0925)
E	2.00 (0.0787)	S	2.40 (0.0945)
F	2.05 (0.0807)	T	2.45 (0.0965)
G	2.08 (0.0819)	U	2.50 (0.0984)
H	2.11 (0.0831)	V	2.55 (0.1004)
J	2.14 (0.0843)	W	2.60 (0.1024)
K	2.17 (0.0854)	X	2.65 (0.1043)
L	2.20 (0.0866)	Y	2.70 (0.01063)
M	2.23 (0.0878)	.	.

Using a plastic hammer, remove the 16 bolts and transaxle housing.

Remove the differential gear from the transaxle case.

Clean the contact surface of the differential case.
Heat the ring gear in water and boil for 10 minutes.
Carefully remove the ring gear from the water.
After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

Install the 8 bolts.

Tighten

Tighten the bolts to 102 N•m (75 lb-ft).

Using transaxle housing oil seal installer DW260-031-01 and a hammer, drive in a new transaxle housing oil seal .

Oil seal in depth : 3.1 mm (0.122 in.)

Using transaxle case oil seal installer DW260-031-02, drive in a new transaxle case oil seal.

Oil seal in depth : 4.3 mm (0.169 in.)