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2008 Chevrolet Aveo - Transmissions > Manual Transaxle > Manual Transaxle - D16 > Repair Inst...

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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.

Click to Enlarge

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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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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Click to Enlarge

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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Click to Enlarge

13. Remove the 2 cage retaining bolts.

14. Remove the 3 transaxle upper mounting bracket bolts.

15. Remove the upper mounting bracket and cage.

Click to Enlarge

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

NOTE

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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).

Click to Enlarge

18. Remove the 3 transaxle upper retaining bolts.

Click to Enlarge

19. Support the transaxle with a transaxle support jack.

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Click to Enlarge

20. Remove the 7 transaxle lower retaining bolts.

Click to Enlarge

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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23. Lower the transaxle.

Installation Procedure

Click to Enlarge

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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3. Install the 7 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).

Click to Enlarge

4. Install the three transaxle upper retaining bolts.


Tighten
Tighten the transaxle upper retaining bolts to 73 Nm (54 lb ft).

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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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Tighten the transaxle upper mounting bracket bolts to 60 Nm (44 lb


ft).

Click to Enlarge

9. Install the 2 rear damping block retaining bolts.


Tighten
Tighten the rear damping block retaining bolts to 55 Nm (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 Nm (59 lb ft).

12. Install the damping block connection nut and bolt.


Tighten

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Tighten the damping block connection nut and bolt to 80 Nm (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 Nm (15 lb ft).

Click to Enlarge

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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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(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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