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    MANUAL TRANSMISSION

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    208 views208 pages

    Manual Transmission

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    Jonattan Javier Ramirez Bolaños

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    © All Rights Reserved
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    2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo SPECIFICATIONS FAST! Fastener Tightening Specifica ER TIGHTENING SPECIFICA’ 2005 TRANSMISSION Manual Transmission - D16 - Aveo Specification Application Metric English Sth Gear Fork Bolts 22Nm 16 Ib ft Sth Gearshift Connector Bolts 7Nan 62 Ib in Backup Lamp Switch 20N.m 15 Ib ft Bearing Plate Bolts 22N.m 16 Ib ft Bearing Retainer Bolts, Right Side 25m 18 Ib ft Bearing-Adjusting Ring-Retainer Plate Bolt 3Nm 44 Tb in Clutch-Release Cylinder Retaining Bolts 20 Nm 15 Ibft Damping Block Connection Nut and Bolt 80 N.m 59 Ib fi Differential Cover Bolts 40 N.m 30 Ib ft Flywheel Inspection Cover Bolts 7Nm 62 1b in Gearshift Housing Bolts 7Nm 62 Ib in Gearshift Lever Cover Bolts 22N.m 16 Ib ft Input Driveshaft Detent Screw 15 Nam IIb ft Rear Damping Block Retaining Bolts 35m 41 Ib ft Rear Mounting Bracket Bolts 80 Nm 59 Ib ft Ring-Gear Bolts 70 N.m 52 Ib ft Rod Clamp Bolt 14N.m 124 Ib in Speedometer Housing Retaining Bolt 4Nm 35 Ib in Speedometer-Driven Gear Bolt 4Nm 35 Ib in Transaxle Cover Bolts 18 Nm 1B Ib ft Transaxle Lower Retaining Bolts (a) 73. Nm 54 Ib ft Transaxle Lower Retaining Bolt (b) 31Nm 23 Ib ft Transaxle Lower Retaining Bolts (c) 21N.m 15 Ib ft Transaxle Upper Retaining Bolts 73. Nm 54 Ib ft Transaxle Upper Mounting Bracket Bolts 60 N.m 44 Ib ft MANUAL TRANSMISSION SPECIFICATIONS Performance - Manual Transaxle Specification 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Application Metric English Final Drive Ratio (1.4L SOHC) 4.17611 Final Drive Ratio (1.4L DOHC) 3.944:1 Final Drive Ratio (1.5L) 3.722:1 Gradeability 0.47 (tan 0) Ist Gear Ratio 3.545:1 2nd Gear Ratio 1,952:1 3rd Gear Ratio 1.2761 4th Gear Ratio (4L DOHC/LSL) 09711 4th Gear Ratio (1.4L SOHC) 0.892:1 Sth Gear Ratio (1.4L DOHC/1.5L) 0.763:1 Sth Gear Ratio (1.4L SOHC) 0.707:1 Reverse Gear Ratio 3.333:1 Maker DWMC Maximum Speed 170 km/H (105.6 mph) Minimum Turning Radius 48m (15.7 ft) Oil Capacity L8 liters 2 quarts Transaxle Type and Model D-16 SCHEMATIC AND ROUTING DIAGRAMS MANUAL TRANSM ION SCHEMATICS. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Courtesy of GENERAL MOTORS CORP. COMPONENT LOCATOR MANUAL TRANSMISSION COMPONENT VIEWS 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 2: Gears And Case Component View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 2 Callout ‘Component Name 1 Retaining Ring 2 Groove Ball Bearing 3 Washer 4 Retaining Ring 5 Sth Speed Gear 6 Needle Cage FT Synchronizer Ring 8 Sth Synchronizer Spring 9 5th Shift sleeve 10 3th Synchronizer Key 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Retaining Ring 12 Main Shaft Dise B Needle Cage 4 Ist Speed Gear 15 Needle Cage 16 Inside Synchronizer Ring 17 Intermediate Ring 18 Outside Synchronizer Ring 19 Cirelip 20 Sliding Gear 21 Ist & 2nd Synchronizer Spring 22 Synchronizer Ring 23 Ist & 2nd Synchronizer Key 24 3rd Speed Gear 25 Needle Cage 26 Washer 27 Washer 28 Washer Retaining Ring 29 Needle Cage 30 2nd Speed Gear 31 Cirelip 32 Washer 33 3rd & 4th Synchronizer Spring 34 4th Speed Gear 35 Washer Retaining Ring 36 Washer 37 Roller Bearing 38 Transaxle Main Shaft 39 Synchronizer Key 40 Shift Sleeve 41 Ball 2 Reverse Idler Gear Shaft B Reverse Idler Gear 44 Washer 45 Retaining Ring 46 Cluster Sth Speed Gear 47 Groove Ball Bearing 48 Cluster Bearing Ring 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Retaining Ring 50 Bolt 51 Input Shaft Cluster Gear 52 Input Drive Shift 53 Needle Sleeve Fig. 3: Bearing Plate Component View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 3 Callout Component Name L Bearing Plate Gasket Detent Sleeve Bolt Strain Bolt Bridge Bolt Transaxle Cover Gasket Bolt Bolt ro]eo]afa}url alesse Transaxle Cover 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo 10 Screw ul Bolt 12 Screw 13, Gear Shift Shoe 14 Bolt 15 Magnet 16 Plug 7 Compression Ring 18 Blocking Pin 19 Bolt 20 Pin 21 Bearing Plate Fig. 4: Differential Gear Component View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 4 Callout Component Name 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo 1 Bolt 2 Differential Gear Bearing Flange 3 O-Ring 4 Shaft Seal Ring 3 Taper Roller Bearing 6 Differential Gear 7 Differential Gear Housing 8 Locking Plate 9 Bolt 10 Differential Bearing Ring u O-Ring 12 Speedometer Drive Gear 13, Bolt 4 Differential Spring Pin 15 Bevel Gear Dise 16 Bevel Differential Gear 17 Differential Gear Shaft 18 Side Gear 19 Washer 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo : Shift Linkage Component View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 5 Callout Component Name 1 Bolt 2 Gear Shift Control 3 Bolt 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo 4 Gear Shift Tube Bellows 5 Clamp 6 Gear Shift Control Mode 7 Bolt 8 Bolt 9 Speedometer Driven Gear - Vehicle Speed Sensor (VSS) 10 Gear Shift Rod Pawl Ul Sth Speed Engaging Piece 12 3rd & 4th Gear Shift Rod B Ist & 2nd Gear Shift Fork 4 Pin 15 3rd & 4th Gear Shift Fork 16 Pin 7 Ist & 2nd Gear Shift Rod 18 Reverse Gear Shift Rod 19 Reverse Gear Shift Fork 20 Pin 21 Differential Gear Cover Gasket 22 Differential Gear Cover 2B Screw 24 Backup Lamp Switch 25 O-Ring 26 Bush 27 Sleeve 28 Pin 29 Pin 30 Gear Shift Cover Gasket 31 Retaining Ring 32 Bush 33 Compression Spring 34 Plate 35 Gear Shift Inter Lever 36 Shift Finger 37 Gear Shift Lever Cover 38 Gear Shift Rod 39 Bolt 40 Pin 41 Clip 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Gear Shift Guide Control B Plug 44 Plug 45 Pin Vehicle Speed Sensor (VSS) MANUAL TRANSMISSION CONNECTOR END VIEWS nnector Part Information « PED 12059595 3-Way F Met ack 150 Series, Sealed (BK)| Circuit Pin Wire Color Number Function A RD 1535 Ignition 1 Voltage B D-GN 817 Vehicle Speed Signal Cc BK 1536 Ground DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSTIC STARTING POINT - MANUAL TRANSMISSION Begin the system diagnosis by reviewing the Symptoms - Manual Transmission Reviewing the symptom information will help you determine the correct symptom diagnostic procedure when a malfunction exists SYMPTOMS - MANUAL TRANSMISSION Symptoms - Manual Transmission Checks Actions Examine for a knock at low speeds. # Replace any worn drive axle CV joints, Replace any worn side gear hub. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Examine for a noise most | Correct any abnormalities in the differential gear. pronounced on turns. Examine for a clunk upon acceleration or deceleration. Tighten any loose engine mounts, Replace any worn drive axle inboard joints. Replace any wor differential pinion shaft in the cé Replace any worn side gear hub in the case Examine foraclunking [Replace any worn outboard CV joint. noise in turns. Examine for a vibration. Replace any rough wheel bearing. Replace any bent drive axle shaft. Replace any out-of-round tires. Balance any unbalanced tire. Replace any worn CY joint in the drive axle shaft. Correct an excessive drive axle angle by adjusting the trim height. Examine for anoise in the] Repl NEUTRAL gear with the Replace any worn clutch-release bearing engine running, Replace any worn input shaft cluster gears. Replace any worn first-gear/bearing. Replace any worn second-gear/bearing. Replace any worn third-gear/bearing any worm cluster bearing shaft. Replace any worn fourth-gear/bearing Replace any worn fifth-gear/bearing. Replace any worn mainshaft bearings. Examine for a noise in the Replace any chipped, scored, or worn first-gear first gear only constant mesh gears. Replace any worn first-second gear synchronizer Replace any wom first-gear/bearing Replace any worn differential-gear/bearing Replace any worn-ring gear Adjust, repair, or replace the shift lever and the rods. Examine for a noise in the Replace any chipped, scored, or worn second-gear second gear only constant mesh gears. Replace any worn first-second gear synchronizer Replace any wom second-gear/bearing Replace any worn differential-gear/bearing 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Replace any worn-ring gear. # Adjust, repair, or replace the shift lever and the rods. Examine for a noise in the]. Replace any chipped, scored, or worn third-gear third gear only. constant mesh gears. « Replace any worn third-fourth gear synchronizer. « Replace any worn third-gear/bearing « Replace any wom differential-gear/bearing. « Replace any worn-ring gear. « Adjust, repair, or replace the shift lever and the rods. Examine for anoise in the}, Replace any chipped, scored, or worn fourth gear or fourth gear only. gear output Replace any worn third-fourth gear synchronizer. # Replace any worn fourth-gear/bearing + Replace any worn differential-gear/bearing. # Replace any worn-ring gear «Adjust, repair, or replace the shift lever and the rods. + Replace any chipped, scored, or worn fifth gear or output gear, # Repair any worn fifth-gear synchronizer. Examine for anoise in the! | Replace any worn fifth-gear/bearing fifth gear only. as » Replace any worn differential-gear/bearing. « Replace any worn-ring gear. + Adjust, repair, or replace the shift lever and the rods. « Replace any chipped, scored, or worn reverse idler gear, idler-gear bushing, input gear, or output gear, Examine for a noise in the] _* Replace any wor first-second gear synchronizer reverse gear only Replace any worn output gear. « Replace any worn differential-gear/bearing. « Replace any worn-ring gear. Add sufficient lubricant Examine for a noise in all « Replace any wom bearings. gears. # Replace any chipped, scored, or worn input-gear shaft or output-gear shaft # Adjust or replace the linkage, as needed. Examine for the transaxle Adjust. repair. or replace any binding shift linkage. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo slipping out of gear. Tighten or replace the input-gear bearing retainer, as needed. Repair or replace any worn or bent shift fork Examine for a leak in the area of the clutch. Repair the transaxle casing. Replace any damaged release bearing guide. F Repair the transaxle casing. Examine for a leak at the a e center of the transaxle. Repair the shift mechanism Replace the damaged backup lamp switch: « Adjust or replace the bearing retainers, Tighten or replace the differential cover. Adjust or replace the drive axle shaft seals. Examine for a leak at the differential. Replace any damaged release-bearing guide. Adjust, repair, or replace the shift mechanism: Adjust, repair, or replace the clutch-release system. Replace any chipped, ored, or worn fifth-gear Examine for a hard shift. synchronizer Replace any chipped, scored, or worn first-second gear synchronizer. Replace any worn third-fourth gear synchronizer. Adjust, repair, or replace the shift lever and the rods. Replace any damaged release-bearing guide Adjust, repair, or replace the clutch-release system Replace the chipped, scored, or worn input shaft/gear- cluster gears. Replace any worn fifth-gear synchronizer. Repl Replace any worn first-gear/bearing Replace any worn first-second gear synchronizer. ; : ce any worn fifth-gear/bearing, Examine for a clashing of gears. Replace any worn second-gear/bearing, Replace any worn third-gear/bearing Replace any worn third-fourth synchronizer. Replace any worn fourth-gear/bearing Replace any wom reverse-idler gear. TRANSMISSION NOISY 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Identify the cause of any noise before attempting to repair the clutch, the transaxle, or their related linkages Symptoms of trouble with the clutch or the manual transaxle include: «A great effort required to shift gears « The sound of gears clashing and grinding + Gear blockout ‘Any of these conditions requires a careful analysis. Make the following checks before disassembling the clutch or the transaxle for repairs. Road Travel Noise Many noises that appear to come from the transaxle may actually originate with other sources such as the: « Tires # Road surfaces Wheel bearings Engine Exhaust system These noises may vary according to the: Size of the vehicle « Type of the vehicle « Amount of insulation used in the body of the vehicle Transaxle Noise Transaxle gears, like any mechanical device, are not absolutely quiet and will make some noise during normal operation To verify suspected transaxle noises: Select a smooth, level asphalt road to reduce tire 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, wrwYNE Determine if the noise occurs while the vehicle operates in: + Drive - under a light acceleration or a heavy pull 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo « Float - maintaining a constant speed with a light throttle on a level road ¢ Coast - with the tran: All of the above le in gear and the throttle partly or fully close Bearing Noise Differenti 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 Other Noise Brinelling A brinelled bearing causes a knock or click approximately every second revolution of the wheel because the bearing rollers do not travel at the same speed as the wheel. In operation, the effect is characterized by a low-pitched noise. A brinelled bearing is caused by excessive thrust which pushes the balls up on the pathway and creates a triangular-shaped spot in the bearing race. A brinelled bearing can also be caused from pressing one race into position by applying pressure on the other race. A false indication of a brinelled bearing occurs as a result of vibration near the area where the bearing is mounted. Brinelling is identified by slight indentations, resulting in a washboard effect in the bearing race Lapping Lapped bearing noise occurs when fine particles of abrasive materials such as scale, sand, or emery circulate through the oil in the vehicle, causing the surfaces of the roller and the race to wear away, Bearings that wear loose but remain smooth, without spalling or pitting, are the result of dirty oil. Locking, Large particles of foreign material wedged between the roller and the race usually causes one of the races to turn, creating noise from a locked bearing. Pre-loading regular taper roller bearings to a value higher than that specified also can result in locked bearings. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Pitting Pitting on the rolling surface comes from normal wear and the introduction of foreign materials. Spalling Spalled bearings have flaked or pitted rollers or races caused by an overload or an incorrect assembly that results in a misalignment, a cocking of bearings, or adjustments that are too tight. After completing these checks, refer to Symptoms - Manual Transmi REPAIR INSTRUCTIONS TRANSMISSION FLUID LEVEL INSPEC Fig. 6: Filler Plug & Fluid Level Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Checking Hot Transmission Fluid through Drain Plug Hole Caution in Cautions and Notices. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo 1. With the vehicle on a level surface and the fluid in the transaxle cold, remove the filler plug and check the fluid level. The fluid should come to the bottom edge of the plug hole Fig. 7: Filler Plug & Differential Gear Cover Courtesy of GENERAL MOTORS CORP. v If the level is low, add SAE 75W-85 GL-4 manual transaxle fluid through the filler plug hole until the fluid begins to run out. w Reinstall the filler plug and tighten it securely 4, If the fluid is contaminated, drain the oil after removing the differential gear cover. SHIFT LINKAGE ADJUSTMENT 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo yyw Fig. 8: Rod Clamp Bolt Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Position the gearshift lever into NEUTRAL. IMPORTANT: All the gears must be easy to engage when the vehicle is stationary, the engine is running, and the clutch is disengaged. 3. Loosen the rod clamp bolt. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 9: Gearshift Rod & Gage Pin Courtesy of GENERAL MOTORS CORP. 4, Remove the adjustment hole plug from the shift lever cover. 5. Tur the gearshift rod and fully insert a 5 mm (0.2 in) gage pin into the adjustment hole. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo 6 Fig. 10: Gage Pin & Gearshift Lever Courtesy of GENERAL MOTORS CORP. Remove the boot from the console. Pull the boot upward to expose the shift control lever mechanism Position the gearshift lever close to the left side of the NEUTRAL position Insert a 5 mm (0.2 in) gage pin into the holes to align the gearshift lever with the gearshift lever housing. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 11: Rod Clamp Bolt Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 10. Tighten the rod clamp bolt Tighten: Tighten the rod clamp bolt to 14 N.m (124 Ib in). 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo il 12. 13. 14, 15. Fig. 12: Gage Pin, Gearshift Lever & Adjustment Hole Courtesy of GENERAL MOTORS CORP. Remove the 5 mm (0.2 in) gage pin from the adjustment hole. Install the adjustment hole plug. Remove the 5 mm (0.2 inch) gage pin from the gearshift lever Install the boot to the console. Connect the negative battery cable. GEARSHIFT CONTROL LEVER REPLACEMENT Removal Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Rene Fig. 13: Lifting Console Cover Upward Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. Disconnect the negative battery cable Position th shift lever into NEUTRAL. Disconnect the boot from the console cover. Lift the console cover upward to expose the shift control lever mechanism 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 14: Gearshift Lever Stop Clamp Courtesy of GENERAL MOTORS CORP. 5, Rotate the gearshift lever stop clamp and remove it 6. Remove the gearshift lever from the gearshift lever shaft Installation Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig, 15: Gearshift Lever Stop Clamp Courtesy of GENERAL MOTORS CORP. Install the gearshift lever into the gearshift lever shaft Install the gearshift lever stop clamp. Rotate the gearshift lever stop clamp to secure it. wenn 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 16: Lifting Console Cover Upward Courtesy of GENERAL MOTORS CORP. 4. Lower the boot and connect it to the console cover. 5. Connect the negative battery cable. GEARSHIFT LEVER CASE REPLACEMENT. Removal Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 17: Gea Courtesy of ift Lever Housing & Bolts .NERAL MOTORS CORP. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. Disconnect the negative battery cable. Remove the rod clamp. Refer to Shift Linkage Adjustment Remove the console. eye rs Remove the gearshift lever housing bolts and the gearshift lever housing Installation Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo 2 3 4 Fig. 18: Gearshift Lever Housing Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. Install the gearshift lever housing and the gearshift lever housing bolts Tighten: Tighten the gearshift housing bolts to 7 N.m (62 Ib in). Adjust the shift linkage. Refer to Shift Linkage Adjustment Install the console. Connect the negative battery cable. SPEEDOMETER DRIVEN GEAR REPLACEMENT Removal Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 19: Speedometer Speed Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 1. Disconnect the speedometer speed sensor electrical connector. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 20: Speedometer Housing & Retaining Bolt Courtesy of GENERAL MOTORS CORP. 2. Remove the speedometer housing retaining bolt. 3. Remove the speedometer-driven gear and the speedometer housing. Installation Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo rome Fig. 21: Speedometer-Driven Gear & Speedometer Housing Courtesy of GENERAL MOTORS CORP. Coat the O-ring with petroleum jelly. Install the speedometer-driven gear and the speedometer housing NOTE: Refer to Fastener Notice in Cautions and Notices. Install the -dometer housing retaining bolt. Tighten: Tighten the speedometer housing retaining bolt to 4 N.m (35 Ib in) 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 22: Speedometer Speed Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 4, Connect the speedometer speed sensor electrical connector SHIFT CONTROL LINKAGE REPLACEMENT, Removal Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo RYONS Fig. 23: Clip, Bolt & Universal Joint Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. Disconnect the negative battery cable. Remove the rod clamp. Refer to Shift Linkage Adjustment Remove the clip and the bolt from the universal joint. Separate the universal joint from the transaxle. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 24: Transaxle Rear Mounting Bracket Courtesy of GENERAL MOTORS CORP. 5. Remove the fixing shaft pin and separate the linkage connection part from the transaxle rear mounting bracket. 6. Remove the shift linkage assembly Installation Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 25: Transaxle Rear Mounting Bracket Courtesy of GENERAL MOTORS CORP. Install the shift linkage assembly Install the fixing shaft pin and connect the linkage connection part to the transaxle rear mounting bracket, 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 26: Clip, Bolt & Universal Joint Courtesy of GENERAL MOTORS CORP. Install the universal joint to the transaxle. 4. Install the clip and the bolt from the universal joint. 5. Install the rod clamp. 6. Adjust the shift linkage. Refer to Shift Linkage Adjustment 7. Connect the negative battery cable. DRIVE AXLE SEAL REPLACEMENT Tools Required KM-519 Ring Installer. See Special Tools Removal Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 27: Removing Axle Seal Using A Pry Bar Courtesy of GENERAL MOTORS CORP. NOTE: While using a pry bar to remove the axle seal, use extreme care not to damage the bearing adjusting ring on the transmission case. 1. Remove the drive axle from the transaxle. Refer to Inner Axle Shaft Replacement - Front Drive Axle in Front Drive Axle. 2, Remove the drive axle seal by lifting the outer lip of the seal with a pry bar Installation Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 28: Installing Drive Axle Seal Using A Hammer & KM-519 Courtesy of GENERAL MOTORS CORP. -519 (1) and a hammer. See Special Install the new drive axle seal using the K Tools 2. Coat the seal lip with the transaxle fluid. 3. Install the drive. Refer to Inner Axle Shaft Replacement - Front Drive Axle in Front Drive Axle. TRANSMISSION REPLACEMENT Tools Required J 28467-B (DW 117) Engine Support Fixture Removal Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 29: Transaxle Rear Mounting Bracket Courtesy of GENERAL MOTORS CORP. Install the J 28467-B Remove the battery and battery tray, Refer to Battery and Battery Tray Replacement in Engine Electrical Remove the shift linkage assembly, Refer to Shift Linkage Adjustment Remove the drive axle shaft, Refer to Inner Axle Shaft Replacement - Front Drive Axle in Front Drive Axle. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 30: Backup Lamp Switch & Speedometer Speed Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 5. Disconnect the backup lamp switch electrical connector. Disconnect the speedometer speed sensor electrical connector. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 31: Removing Clutch Release Cylinder & Retaining Bolts Courtesy of GENERAL MOTORS CORP. 7, Remove the clutch release cylinder retaining bolts and the clutch release cylinder. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo 10. ‘\ VES ’ Fig, 32: Removing Rear Mounting Bracket & Bolts Courtesy of GENERAL MOTORS CORP. Remove the damping block connection nut and bolt. Remove the 3 rear mounting bracket bolts. Remove the rear mounting bracket from the transaxle 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 33: Removing Rear Damping Block & Retaining Bolts Courtesy of GENERAL MOTORS CORP. L1, Remove the 2 rear damping block retaining bolts. 12, Remove the rear damping block from the front cross member, 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 34: Removing Transaxle Upper Mounting Bracket & Bolts Courtesy of GENERAL MOTORS CORP. 13. Remove the 2 cage retaining bolts. 14. Remove the 3 transaxle upper mounting bracket bolts. 15. Remove the upper mounting bracket and cage 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 35: Removing Transaxle Upper & Retaining Bolts Courtesy of GENERAL MOTORS CORP. 16, Remove the 3 transaxle upper retaining bolts 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 36: Transaxle Support Jack & Transaxle Courtesy of GENERAL MOTORS CORP. 17. Support the transaxle with a transaxle support jack 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 37: Removing Transaxle Lower & Retaining Bolts Courtesy of GENERAL MOTORS CORP. 18, Remove the 7 transaxle lower retaining bolts 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 38: Transaxle & Engine Block Courtesy of GENERAL MOTORS CORP. IMPORTANT: Rest the transaxle only in an upright position 9, Remove the transaxle Slide the transaxle sideways away from the engine block Nee 8 1. Lower the transaxle. Installation Procedure 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo 1 2 Fig. 39: Transaxle & Engine Block Courtesy of GENERAL MOTORS CORP. Support the transaxle with a transaxle support jack Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 40: Installing Transaxle Lower & Retaining Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the 7 transaxle lower retaining bolts. Tighten: « Tighten the transaxle lower retaining bolts to 73 N.m (54 Ib ft). « Tighten the transaxle lower retaining bolt to 31 N.m (23 Ib ft) Tighten the transaxle lower retaining bolt to 21 N.m (15 Ib ft). 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 41: Installing Transaxle Upper & Retaining Bolts Courtesy of GENERAL MOTORS CORP. 4. Install the three transaxle upper retaining bolts. Tighten: Tighten the transaxle upper retaining bolts to 73 N.m (54 Ib ft) 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 42: Installing Transaxle Mounting Bracket & Bolts Courtesy of GENERAL MOTORS CORP. 5. Install the cage retaining bolt and cage. 6. Install the three transaxle upper mounting bracket bolts and bracket. Tighten: Tighten the transaxle upper mounting bracket bolts to 60 N.m (44 Ib ft) 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 43: Installing Rear Damping Block & Retaining Bolts Courtesy of GENERAL MOTORS CORP. Install the 2 rear damping block retaining bolts. Tighten: Tighten the rear damping block retaining bolts to 55 N.m (41 Ib ft) Install the rear damping block from the front cross member. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 44: Installing Rear Mounting Bracket & Bolts Courtesy of GENERAL MOTORS CORP. Install the 3 rear mounting bracket bolts and the bracket. Tighten: Tighten the rear mounting bracket bolts to 80 N.m (59 Ib ft). 10, Install the damping block connection nut and bolt. Tighten: Tighten the damping block connection nut and bolt to 80 N.m (59 Ib ft) 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 45: Installing Clutch Release Cylinder & Retaining Bolts Courtesy of GENERAL MOTORS CORP. 11. 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 Ib ft). 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 46: Backup Lamp Switch & Speedometer Speed Sensor Electrical Connector Courtesy of GENERAL MOTORS CORP. 12. Connect the speedometer speed sensor electrical connector 13. Connect the backup lamp switch electrical connector. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 47: Transaxle Rear Mounting Bracket Courtesy of GENERAL MOTORS CORP. 14. Remove the J 28467-B 15. Install the drive axle shaft. Refer to Inner Axle Shaft Replacement - Front Drive Axle in Front Drive Axle. 16, Install the shift linkage assembly. Refer to Shift Control Linkage Replacement 17. Install the battery and battery tray. Refer to Battery and Battery Tray Replacement in Engine Electrical 8, Inspect the fluid level, Refer to Transmission Fluid Level Inspection TRANSMISSION DISASSEMBLE Tools Required « J 6125-B Slide Hammer. See Special Tools e J 22888-20A Bearing Puller with J 22888-35 Puller Legs. See Special Tools « KM-553-A Fifth Gear Puller. See Special Tools e J 36633 Snap Ring Retainer. See Special Tools 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo « J 3289-20 (KM 113-2) Holding Fixture. See Special Tools « J 42469 Shift Rod Remover. See Special Tools « KM-552 Fixture. See Special Tools Disassembly Procedure Fig. 48: Removing Transaxle Courtesy of GENERAL MOTORS CORP. 1. Remove the transaxle from the vehicle. Refer to Transmission Replacement Remove the filler plug at the cover. N 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 49: Gearshift Lever C & Bolts Courtesy of GENERAL MOTORS CORP. 3. Remove the bolts from the gearshift lever cover. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 50: Locating Gearshift Lever Cover Courtesy of GENERAL MOTORS CORP. 4, Remove the gearshift lever cover 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 51: Gearshift Lever Cover, KM-552 & J 3289-20 Courtesy of GENERAL MOTORS CORP. 5. Bolt the gearshift lever cover to the KM-5S2 (1). See Special Tools 6. Position the KM-552 into the J 3289-20 (2). See Special Tools 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Ns l/ Fig. 52: Snap Ring, Bushing, Spring & Intermediate Lever Courtesy of GENERAL MOTORS CORP. 7. Remove the snap ring, the bushing, the spring, and the intermediate lever 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 53: Shift Finger Lever Pin Courtesy of GENERAL MOTORS CORP. 8, Remove the shift finger lever pin (2). 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo 9. Remove the gearshift rod (1) and the shift finger lever 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 5S: Locating Speedometer-Driven Gear Courtesy of GENERAL MOTORS CORP. 10, Remove the bolt and the speedometer-driven gear from the transaxle housing 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Transaxle Cover Bolts sy of GENERAL MOTORS CORP. 11. Remove the transaxle cover bolts. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 57: Removing End Cover Courtesy of GENERAL MOTORS CORP. 12, Remove the transaxle cover. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 58: Bearing Plate Bolts Courtesy of GENERAL MOTORS CORP. 13. Shift the transaxle into 2nd gear 14, Remove the bearing plate bolts. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 59: View Of Transmission Courtesy of GENERAL MOTORS CORP. 15, Remove the bearing plate from the case with the shafts attached 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo a7, Wie eT Fig. 60: Bearing Plate, KM-552 & J 3289-20 Courtesy of GENERAL MOTORS CORP. 16. Shift the transaxle into reverse (R). 17. Bolt the bearing plate to the KM-SS2 (2) and install the KM-552 (2) into the J 3289-20 (1). See Special Tools 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 61: 5th Gear Fork & Bearing Plate Courtesy of GENERAL MOTORS CORP. 18. Remove the bolts and the Sth gear fork from the bearing plate. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 62: Mainshaft-Driven 5th Speed Assembly Snap Ring Courtesy of GENERAL MOTORS CORP. 19, Remove the mainshaft-driven 5th speed assembly snap ring, 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 63: 5th Driven Gear Synchronizer, Sleeve & J22888-20A Courtesy of GENERAL MOTORS CORP. 20. Remove the Sth driven gear synchronizer sleeve and the synchronizer gear using the J 22888-20A (1) with the puller legs J 22888-35. See Special Tools 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 64: Mainshaft-Driven 5th Gear Assembly Courtesy of GENERAL MOTORS CORP. 21. Remove the mainshafi-driven Sth gear assembly (4) 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 65: Brass Synchronizer Ring Courtesy of GENERAL MOTORS CORP. 22. Remove the brass synchronizer ring. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 66: Needle Bearing, Retaining g & Thrust Washers Courtesy of GENERAL MOTORS CORP. 23. Remove the needle bearing, the retaining ring, and the thrust washers. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 67: Input Drive Sth Gear Snap Ring Courtesy of GENERAL MOTORS CORP. 24, Remove the input drive Sth gear snap ring. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 68: Input Drive 5th Gear & KM-553-A Courtesy of GENERAL MOTORS CORP. 25, Remove the input drive Sth gear using the KM-553-A (1). See Special Tools 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 69: 5th Gearshift Connector & Bolts Courtesy of GENERAL MOTORS CORP. 26. Remove the bolts and the Sth gearshift connector from the bearing plate using the pawl 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 70: Shift-Rod Plugs, J 42469 & J 6125-B Courtesy of GENERAL MOTORS CORP. 27. Remove the 4 shift-rod plugs using the J 42469 (1) and the J 6125-B (2). See Special Tools 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 71: Spring & Rod Lock Pin Courtesy of GENERAL MOTORS CORP. 28, Remove the spring and the rod lock pin from the small plug hole 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 72: Pin & Gearshift Rod/Fork Assembly Courtesy of GENERAL MOTORS CORP. 29, Remove the pin from the reverse gearshift rod/fork assembly 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 73: Reverse Gearshift Rod/Fork Assembly & Bearing Plate Courtesy of GENERAL MOTORS CORP. 30. Remove the reverse gearshift rod/fork assembly from the bearing plate 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 74: Support Bracket & Bolts Courtesy of GENERAL MOTORS CORP. 31. Remove the bolts from the support bracket 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 75: Ist-2nd Gearshift Fork & Holding Pin Courtesy of GENERAL MOTORS CORP. 2 pin. 32. Remove the Ist-2nd gearshift fork holdin, 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 76: Ist-2nd Gearshift Rod & Bearing Plate Courtesy of GENERAL MOTORS CORP. 33. Drive the Ist-2nd gearshift rod out until it is just free of the bearing plate. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 77: Support Bracket & Bearing Plate Courtesy of GENERAL MOTORS CORP. 34. Remove the support bracket from the bearing plate 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 78: 3rd-4th Gearshift Fork, Rod & Holding Pin Courtesy of GENERAL MOTORS CORP. 35. Remove the 3rd-4th gearshift fork holding pin and the 3rd-4th gearshift rod 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 79: 5th Gearshift Lever & Bearing Plate Courtesy of GENERAL MOTORS CORP. 36, Remove the Sth gearshift lever from the bearing plate. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 80: Ist-2nd Gearshift Rod Courtesy of GENERAL MOTORS CORP. 37. Remove the Ist-2nd gearshift rod. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 81: Mainshaft & J 36633 Courtesy of GENERAL MOTORS CORP. 38. Compress the snap ring holding the mainshaft and secure it with the J 36633 (1). See Special Tools 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig, 82: Input Shaft & Snap Ring Pliers Courtesy of GENERAL MOTORS CORP. 39. Hold the snap ring open at the base of the input shaft using the snap ring pliers (2) 40, Remove the mainshaft assembly and the input shaft assembly from the bearing plate. INPUT SHAFT DISASSEMBLE Tools Required J.22912-01 Universal Bearing Puller. See Special Tools 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 83: Detent Screw & Input Driveshaft Courtesy of GENERAL MOTORS CORP. 1, Remove the detent screw at the end of the input driveshaft. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 84: Snap Ring & Gear Cluster Courtesy of GENERAL MOTORS CORP. 2. Remove the snap ring at the base of the gear cluster. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 85: Input Driveshaft Cluster Gear & J 22912-01 Courtesy of GENERAL MOTORS CORP. we Press the input driveshaft from the input shaft cluster gear using the J 22912-01 (1). See Special Tools 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 86: Cluster Shaft Bearing & J Courtesy of GENERAL MOTORS 4. Remove the cluster shaft bearing from the input shaft gear cluster using theJ 22912-01 (1). See Special Tools INPUT SHAFT ASSEMBLE 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Th WILL / aa Fig. 87: Cluster Shaft Bearing & Input Shaft Gear Cluster Courtesy of GENERAL MOTORS CORP. 1. Press the cluster shaft bearing onto the input shaft gear cluster. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo CT Fig. 88: Input Driveshaft & Input Shaft Gear Cluster Assembly Courtesy of GENERAL MOTORS CORP. 2. Press the input driveshaft into the input shaft gear cluster assembly 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 89: Snap Ring & Gear Cluster Courtesy of GENERAL MOTORS CORP. 3. Install the snap ring at the base of the gear cluster. 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Fig. 90: Detent Screw & Input Driveshaft Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 4. Install the detent screw at the end of the input driveshaft. Tighten: Tighten the input driveshaft detent screw to 15 N.m (11 Ib ft) MAINSHAFT DISASSEMBLE Tools Required J. 22912-01 Universal Bearing Puller. See Special Tools 2005 Chevrolet Aveo 2005 TRANSMISSION Manual Transmission - D16 - Aveo Mean q tat Cn | : Mainshaft Bearing & J 22912-01 sy of GENERAL MOTORS CORP. 1, Remove the mainshaft bearing using the J 22912-01 (1). See Special Tools Gay SS SSO ABE Fig. a:

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