Service Manual2011 Aveo FIVE-SPEED MANUAL TRANSAXLE (Y4M HD)

SECTION 5B2

FIVE-SPEED MANUAL TRANSAXLE (Y4M HD)

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted.

SPECIFICATIONS

General Specifications

Application	Description		Unit	Standard	Limit
General	Type	Forward gear	-	Synchronized mesh type	-
	.	Reverse gear	-	Sliding mesh type	-
	Gear ratio	1st	-	3.539	-
		.	2nd	-	1.952	-
		.	3rd	-	1.323	-
		.	4th	-	0.974	-
		.	5th	-	0.781	-
		.	Reverse	-	3.385	-
	Final drive ratio		-	4.048	-
	Fluid capacity		L(qt)	2.1 (2.21)	-
	Fluid classification		-	SAE 75W85W	-
Service	Shift fork end thickness	Low speed shift fork (1st~2nd)	mm (in.)	8.7 (0.343)	8.56 (0.337)
	.	High speed shift fork (3rd~4th)	mm (in.)	7.8 (0.307)	7.66 (0.302)
	.	5th gear shift fork	mm (in.)	7.8 (0.307)	7.66 (0.302)
	Clearance between gear and synchronizer ring		mm (in.)	1.0 (0.039)	0.5 (0.020)
	Clearance between sleeve and shift fork		mm (in.)	0.2-0.6 (0.008-0.024)	1.0 (0.039)
	Thrust free play of differential side gear		mm (in.)	0.03-0.4 (0.001-0.016)	-
	Speedometer gear ratio(Driven/Drive)		-	17/18 (0.944)	-

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
5th/Reverse Gear Shift Shaft Bolt	10-16	7-12	-
Back Up Light Switch Nut	15-18	11-13	-
Counter Shaft 5th Gear Nut	60-80	44-59	-
Crankshaft Position Sensor Bolt	5-8	-	44-70
Differential Ring Gear Bolt	80-100	59-74	-
High Speed Shift Shaft Bolt	10-16	7-12	-
Low Speed Shift Shaft Bolt	10-16	7-12	-
Oil Drain Plug	20-30	15-22	-
Oil Level Plug	20-30	15-22	-
Reverse Idle Gear Shaft Bolt	18-28	13-21	-
Reverse Shift Lever Bolt	18-28	13-21	-
Cable Bracket Bolt	18-28	13-21	-
Left Case Plate Screw	8-9	-	71-80
Shift Interlock Bolt	18-28	13-21	-
Side Cover Bolt	8-12	-	71-106
Speedometer Driven Gear Bolt	4-7	-	35-62
Transaxle Case Bolt	15-22	11-16	-
Transaxle Lower Bolt (Engine Side)	55-65	41-48	-
Transaxle Mounting Bracket Bolts	55-65	41-48	-
Transaxle Upper Bolt (Engine Side)	55-65	41-48	-
Rear Damping Block Retaining Bolts	50-60	37-44	-
Rear Mounting Bracket Bolts	55-65	41-48	-
Damping Block Connection Nut and Bolt	75-95	55-70	-
Clutch Housing Lower Plate Bolts	10	-	89
Gear Shift Control Lever Assembly Bolts	5-10	-	44-89

SPECIAL TOOLS

Special Tools Table

	09913-76010 Bushing, Seal Installer
	DT-49079 Gear, Bearing Installer
	DW09921-57810 Gear, Bearing Remover
	DT-49080 Gear, Bearing Installer
	DT-49081 Gear, Bearing Installer
	DW09940-53111 Gear, Bearing Installer
	DW09943-78210 Bushing, Seal Installer
	EN-48356 Engine Fixture
	DW220-020A-01 Differential Bearing Puller
	DW220-020A-02 Differential Bearing Plate Adapter
	DW220-020A-03 Differential Bearing Plate Adapter
	DT-49082 Needle Bearing Remover
	DT-49084 Input Shaft Holder
	DT-49088 Oil Seal Installer
	KM519 Oil Seal Installer
	DT-49083 Needle Bearing Installer

DIAGNOSIS

General Diagnosis

Condition	Probable Cause	Correction
Gear Slipping Out of Mesh	Worn shift fork.	Replace shift fork.
	Worn synchronizer sleeve or gear.	Replace sleeve or gear.
	Worn bearings on input shaft or counter shaft.	Replace bearing.
	Weakened or damaged location spring.	Replace spring.
	Loose or damaged synchronizer spring.	Replace synchronizer spring.
	Excessive back-lash of gear.	Adjust back-lash of gear.
Gear Catching	Bent or distorted shift shaft or shift fork.	Replace shift shaft or shift fork.
Hard Shifting	Worn synchronizer ring.	Replace synchronizer ring.
	Worn synchronizer sleeve or gear.	Replace sleeve or gear.
	Bent or distorted shift shaft.	Replace shift shaft.
	Excessive free travel of all gears in axial direction.	Replace gear.
	Worn bearings on input shaft or counter shaft.	Replace bearing.
	Poor adjustment of clutch cable.	Adjust clutch cable.
	Distorted or broken clutch disc.	Replace clutch disc.
	Damaged clutch cover.	Replace clutch cover.
Noise in the Neutral Gear	Insufficient lubricant.	Supply lubricant.
	Worn input shaft gear.	Replace gear.
	Worn bearings on the input shaft gears.	Replace bearing.
	Worn clutch release bearing.	Replace clutch release bearing.
Noise in the All Gears	Insufficient lubricant.	Supply lubricant.
	Worn bearings on input shaft or counter shaft.	Replace bearing.
	Worn input shaft or counter shaft gear.	Replace gear.
	Worn or damaged synchronizer ring.	Replace synchronizer ring.
	Worn or damaged synchronizer sleeve.	Replace synchronizer sleeve.
	Worn differential gear or bearing.	Replace gear or bearing.
Noise in the Peculiar Gear	Worn or damaged synchronizer ring in the peculiar gear.	Replace synchronizer ring.
	Worn or damaged gear in the peculiar gear.	Replace gear.
	Worn or damaged bearing in the peculiar gear.	Replace bearing.
Leak of Lubricant	Damaged oil seal.	Replace oil seal.

Checking Fluid Level

Check for a leak in the area of transaxle case and sealing and then check fluid level and condition after removing oil level plug.

Operate the engine until it comes to normal operating temperature(Coolant temperature : 80~90°C (176~ 194°F)).
Stall the engine and raise the vehicle.
Remove the oil level plug and check the fluid level.
The fluid should slightly flow out from the oil level plug hole.
If the level is low, add the recommended fluid through the oil level plug hole until the fluid begins to run out.
If the fluid is contaminated or discolored, replace it with the recommended fluid.
Install a new oil level plug.

Tighten

Tighten the oil level plug to 20-30 N•m (15-22 lb-ft).

Changing Fluid

Operate the engine until it comes to normal operating temperature(Coolant temperature : 80~90°C (176~ 194°F)).
Stall the engine and raise the vehicle.
Drain the fluid after removing the drain plug.
Install a new drain plug.

Tighten

Tighten the drain plug to 20-30 N•m (15-22 lb-ft).

Remove the oil level plug and replenish the fluid until it begins to run out.

a. Oil drain plug.

b. Oil level plug.

Install a new oil level plug.

Tighten

Tighten the oil level plug to 20-30 N•m (15-22 lb-ft).

Fluid Specification	SAE 75W85W
Fluid Capacity	2.1L (2.21qt)
Service interval	Refer to Owner's Manual

Checking Transaxle Noise

Many noises that appear to come from the transaxle may actually originate with other sources such as tires, road surfaces, wheel bearings, or engine and exhaust system.

Identify the cause of any noise before attempting to repair the clutch, the transaxle, or their related linkages.

To verify suspected transaxle noises,

Select a smooth, level asphalt road to reduce tyre and resonant body noise.
Drive the vehicle far enough to warm up all the lubricants thoroughly.
Record the speed and the gear range of the transaxle when the noise occurs.
Check for noises with the vehicle stopped, but with the engine running.
Determine if the noise occurs while the vehicle operates in.

Drive - Under a light acceleration or a heavy pull.
Float - Maintaining a constant speed with a light throttle on a level road.
Coast - With the transaxle in gear and the throttle partly or fully closed.
All of the above.

Checking Bearing Noise

Differential Side Bearing Noise

Differential side bearing noise and wheel bearing noise can be confused easily. Since side bearings are pre-loaded, a differential side bearing noise should not diminish much when the differential/transaxle is run with the wheels off the ground.

Wheel Bearing Noise

Wheel bearings produce a rough growl or grating sound that will continue when the vehicle is coasting and the transaxle is in NEUTRAL. Since wheel bearings are not pre-loaded, a wheel bearing noise should diminish considerably when the wheels are off the ground.

COMPONENT LOCATORS

Gear Shift Control

Gear Shift Control Lever Knob
Gear Shift Control Lever Assembly
Select and Shift Cable

Input Shaft and Counter Shaft Gear

Input Shaft Circlip
5th Gear Synchronizer Hub Plate
5th Gear Synchronizer Sleeve
5th Gear Synchronizer Hub
5th-Reverse Synchronizer rever
5th Gear Synchronizer Ring
Input Shaft 5th Gear
Input Shaft 5th Gear Bearing
Input Shaft 5th Gear Spacer
Input Shaft Bearing-Left
Input Shaft 4th Gear
4th Gear Synchronizer Ring
Input Shaft 4th Gear Bearing
3rd-4th Gear Synchronizer Circlip
3rd-4th Gear Synchronizer Sleeve
3rd-4th Gear Synchronizer Key Unit
3rd-4th Gear Synchronizer Hub
3rd Gear Synchronizer Ring
Input Shaft 3rd Gear
Input Shaft 3rd Gear Bearing
Input Shaft
Input Shaft Bearing-Right
Input Shaft Oil Seal
Reverse Gear Shaft Bolt
Reverse Gear Shaft
Reverse Idle Gear
Counter Shaft Nut
Counter Shaft 5th Gear
Counter Shaft Bearing Shim
Counter Shaft Bearing-Left
Counter Shaft 4th Gear
Counter Shaft 3rd-4th Gear Spacer
Counter Shaft 3rd Gear
Counter Shaft 2nd Gear
2nd Gear Synchronizer Ring
Counter Shaft 2nd Gear Bearing
1st-2nd Gear Synchronizer Circlip
1st-2nd Gear Synchronizer Sleeve
1st-2nd Gear Synchronizer Key Unit
1st-2nd Gear Synchronizer Hub
1st Gear Synchronizer Ring
Counter Shaft 1st Gear
Counter Shaft 1st Gear Bearing
Counter Shaft 1st Gear Spacer
Counter Shaft
Counter Shaft Bearing-Right

Gear Shift Fork

Shift and Select Shaft
Shift Interlock Bolt
Shift Lever
Bracket
Low Speed Shift Fork
Low Speed Shift Shaft
Low Speed Shift Shaft Spring/Ball
Low Speed Shift York
High Speed Shift York
High Speed Shaft Spring/Ball
High Speed Shift Shaft
High Speed Shift Fork
Reverse Shift Arm
5th/Reverse Shift Ball
5th/Reverse Shift Shaft Spring/Ball
Reverse Shift Shaft Guide Spring/Ball
5th/Reverse Shift Shaft
5th/Reverse Shift York
5th/Shift Fork
Reverse Shift Lever

Differential and Case

Speedometer Driven Gear
Transaxle Case(Right)
Back Up Light Switch
Transaxle Case(Left)
Oil Gutter
Left Case Plate
Side Cover
Oil Level Plug
Oil Drain Plug
Differential Oil Seal(Left)
Differential Ring Gear
Differential Bearing(Left)
Differential Case
Speedometer Drive Gear
Differential Bearing(Right)
Differential Oil Seal(Right)
Differential Pinion Gear Shaft Pin
Differential Side Gear Adjust Shim
Differential Side Gear
Differential Pinion Gear Shaft
Differential Pinion Gear
Differential Pinion Gear Washer