Repair Instructions - On Vehicle

Document ID: 2093734
Page 1 of 3
2009 Chevrolet Aveo
| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Transmission | Manual Transmission - D16 | Repair Instructions - On Vehicle | Document ID: 2093734
Gearshift Control Lever Replacement

Removal Procedure
Warning: Refer to Battery Disconnect Warning in the Preface section.
1. 2. 3. 4.
Disconnect the negative battery cable. Position the gearshift lever into NEUTRAL. Disconnect the boot from the console cover. Lift the console cover upward to expose the shift control lever mechanism.
2010 General Motors Corporation. All rights reserved.
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5. Rotate the gearshift lever stop clamp and remove it. 6. Remove the gearshift lever from the gearshift lever shaft.
Installation Procedure
1. Install the gearshift lever into the gearshift lever shaft. 2. Install the gearshift lever stop clamp. 3. Rotate the gearshift lever stop clamp to secure it.
4. Lower the boot and connect it to the console cover.
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5. Connect the negative battery cable.
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2009 Chevrolet Aveo
Gearshift Lever Case Replacement

Removal Procedure
1. 2. 3. 4.
Disconnect the negative battery cable. Remove the rod clamp. Refer to Shift Linkage Adjustment. Remove the console. Remove the gearshift lever housing bolts and the gearshift lever housing.
Caution: Refer to Fastener Caution in the Preface section.
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1. 2. 3. 4. 5.
Install the gearshift lever housing. Install the gearshift lever housing bolts and tighten to 7 Nm (62 lb in). Adjust the shift linkage. Refer to Shift Linkage Adjustment. Install the console. Connect the negative battery cable.
Page 1 of 2
2009 Chevrolet Aveo
Speedometer Driven Gear Replacement

Removal Procedure
1. Disconnect the speedometer speed sensor electrical connector.
2. Remove the speedometer housing retaining bolt. 3. Remove the speedometer-driven gear and the speedometer housing.
Installation Procedure 2010 General Motors Corporation.
All rights reserved.
Page 2 of 2
1. Coat the O-ring with petroleum jelly. 2. Install the speedometer-driven gear and the speedometer housing. Caution: Refer to Fastener Caution in the Preface section. 3. Install the speedometer housing retaining bolt and tighten to 4 Nm (35 lb in).
4. Connect the speedometer speed sensor electrical connector.
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2009 Chevrolet Aveo
Shift Control Linkage Replacement

Removal Procedure
1. 2. 3. 4.
Disconnect the negative battery cable. Remove the rod clamp. Remove the clip and the bolt from the universal joint. Separate the universal joint from the transaxle.
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5. Remove the fixing shaft pin and separate the linkage connection part from the transaxle rear mounting bracket. 6. Remove the shift linkage assembly.
1. Install the shift linkage assembly. 2. Install the fixing shaft pin and connect the linkage connection part to the transaxle rear mounting bracket.
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3. 4. 5. 6. 7.
Install the universal joint to the transaxle. Install the clip and the bolt from the universal joint. Install the rod clamp. Adjust the shift linkage. Refer to Shift Linkage Adjustment. Connect the negative battery cable.
Page 1 of 2
2009 Chevrolet Aveo
Drive Axle Seal Replacement

Special Tools
KM-519 Ring Installer
Removal Procedure
Caution: 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 Front Drive Axle Inner Shaft Replacement. 2. Remove the drive axle seal by lifting the outer lip of the seal with a pry bar.
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1. Install the new drive axle seal using the KM-519 (1) and a hammer. 2. Coat the seal lip with the transaxle fluid. 3. Install the drive. Refer to Front Drive Axle Inner Shaft Replacement.
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2009 Chevrolet Aveo
Transmission Replacement
Special Tools
J 28467-B Universal Engine Support Fixture
Removal Procedure
1. 2. 3. 4.
Install J 28467-B . Remove the battery and battery tray. Remove the shift linkage assembly. Refer to Shift Control Linkage Replacement. Remove the drive axle shaft. Refer to Front Drive Axle Inner Shaft Replacement.
Page 2 of 10
5. Disconnect the backup lamp switch electrical connector. 6. Disconnect the speedometer speed sensor electrical connector.
7. Remove the clutch release cylinder retaining bolts and the clutch release cylinder.
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8. Remove the damping block connection nut and bolt. 9. Remove the rear mounting bracket bolts. 10. Remove the rear mounting bracket from the transaxle.
11. Remove the rear damping block retaining bolts. 12. Remove the rear damping block from the front cross member.
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13. Remove the cage retaining bolts. 14. Remove the transaxle upper mounting bracket bolts. 15. Remove the upper mounting bracket and cage.
16. Remove the transaxle upper retaining bolts.
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17. Support the transaxle with a transaxle support jack.
18. Remove the transaxle lower retaining bolts.
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Note: Rest the transaxle only in an upright position 19. Remove the transaxle. 20. Slide the transaxle sideways away from the engine block. 21. Lower the transaxle.
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.
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Caution: Refer to Fastener Caution in the Preface section.
3. Install the transaxle lower retaining bolts. Tighten Tighten the transaxle lower retaining bolts (1) to 73 Nm (54 lb ft). Tighten the transaxle lower retaining bolts (2) to 31 Nm (23 lb ft). Tighten the transaxle lower retaining bolt (3) to 21 Nm (15 lb ft).
4. Install the transaxle upper retaining bolts and tighten to 73 Nm (54 lb ft).
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5. Install the cage retaining bolt and cage. 6. Install the transaxle upper mounting bracket. 7. Install the transaxle upper mounting bracket bolts and tighten to 60 Nm (44 lb ft).
8. Install the rear damping block retaining bolts and tighten to 55 Nm (41 lb ft). 9. Install the rear damping block from the front cross member.
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10. Install the rear mounting bracket and bracket bolts and tighten to 80 Nm (59 lb ft). 11. Install the damping block connection nut and bolt and tighten to 80 Nm (59 lb ft) .
12. Install the clutch release cylinder. 13. Install the clutch release cylinder bolts and tighten to 20 Nm (15 lb ft).
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14. Connect the speedometer speed sensor electrical connector. 15. Connect the backup lamp switch electrical connector.
16. 17. 18. 19. 20.
Remove J 28467-B Install the drive axle shaft. Refer to Front Drive Axle Inner Shaft Replacement. Install the shift linkage assembly. Refer to Shift Control Linkage Replacement. Install the battery and battery tray. Inspect the fluid level. Refer to Transmission Fluid Level Inspection.

Repair Instructions - On Vehicle

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Repair Instructions - On Vehicle

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Document ID: 2093734

2009 Chevrolet Aveo

Gearshift Control Lever Replacement

2010 General Motors Corporation. All rights reserved.

Document ID: 2093734

4. Lower the boot and connect it to the console cover.

Document ID: 2093734

5. Connect the negative battery cable.

Document ID: 2093735

2009 Chevrolet Aveo

Gearshift Lever Case Replacement

2010 General Motors Corporation. All rights reserved.

Document ID: 2093735

Document ID: 2093764

2009 Chevrolet Aveo

Speedometer Driven Gear Replacement

1. Disconnect the speedometer speed sensor electrical connector.

Installation Procedure 2010 General Motors Corporation.

All rights reserved.

Document ID: 2093764

4. Connect the speedometer speed sensor electrical connector.

Document ID: 2093767

2009 Chevrolet Aveo

Shift Control Linkage Replacement

2010 General Motors Corporation. All rights reserved.

Document ID: 2093767

Document ID: 2093767

Document ID: 2093771

2009 Chevrolet Aveo

Drive Axle Seal Replacement

2010 General Motors Corporation. All rights reserved.

Document ID: 2093771

Document ID: 2093773

2009 Chevrolet Aveo

2010 General Motors Corporation. All rights reserved.

Document ID: 2093773

Document ID: 2093773

Document ID: 2093773

16. Remove the transaxle upper retaining bolts.

Document ID: 2093773

17. Support the transaxle with a transaxle support jack.

18. Remove the transaxle lower retaining bolts.

Document ID: 2093773

Document ID: 2093773

Caution: Refer to Fastener Caution in the Preface section.

Document ID: 2093773

Document ID: 2093773

Document ID: 2093773

16. 17. 18. 19. 20.

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