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Home >> Chevrolet >> 2007 >> Optra (CANADA) L4-2.0L >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Overhaul >> Aisin 81-40LE - Automatic Transaxle >> 13. Assemble >> Part 1

Part 1




Transmission Assemble

Tools Required
* DT 46451 (DW240-020) Brake Clutch Spring Compressor
* DT 46454 (DW240-050) Overdrive Brake Adapter
* DT 46455 (DW240-060-01) Brake Spring Compressor Bolt/Nut
* DT 46456 (DW240-060-02) Brake Spring Compressor Plate
* DT 46457 DW240-070) 1st/Reverse Brake Adapter
* DT 46458 2nd Brake Adapter
* DT 46460 (DW240-100) Counter Drive Gear Installation Adapter
* DT 46461 (DW240-130) Differential Preload Adapter
* DT 46462 (DW240-140) Transaxle Housing Side Bearing Outer Race Adapter
* DT 46464 (DW240-160) Transaxle Case Outer Tapered Roller Bearing Race Adapter
* DT 46465 Adapter Handle
* DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer
* DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket
* DT 47521 (DW 260-031-02) Transaxle Case Oil Seal Installer

Assembly Procedure




1. Install 4 new O-rings to the 4 screw plugs.

Notice: Refer to Fastener Notice Fastener Notice.

2. Install the 4 screw plugs with the O-rings to the transaxle rear cover.

Tighten the screw plugs to 7.4 Nm (65 lb in).




3. Install the 2 seal rings to the transaxle rear cover.




4. Using the vernier calipers, measure the free length of the overdrive (O/D) brake piston return spring together with the spring seat.

The standard free length is 18.99 mm (0.7476 in).




5. Coat 2 new O-rings (1) with automatic transaxle fluid (ATF), install them to the O/D brake piston.





Important: Be careful not to damage the O-rings of the O/D brake piston.


6. Coat the O/D brake piston with ATF, install it to the transaxle rear cover.





Notice: In order to prevent damage to the brake piston, do not depress the brake piston lower than 1-2 mm (0.039-0.078 in) beyond the snap ring groove.

7. Using the DT 46451 (1), DT 46454 (2) and a driver, install the O/D brake return spring and snap ring to the transaxle rear cover.




8. Using the DT 46462 (2), DT 46465 (1), install a new side bearing outer race into the transaxle housing.




9. Using the DT 46471 (1) and a hammer, drive in a new transaxle housing oil seal.

The oil seal in depth is 3.1 mm (0.122 in).





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


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




11. Install the transaxle lube apply pipe and differential gear lube apply pipe to the transaxle housing.
12. Install the No. 1 transaxle apply pipe clamp to the transaxle housing with the bolt.

Tighten the bolts to 5.4 Nm (48 lb in).




13. Install the oil reservoir lock plate to the transaxle housing with the 3 bolts.

Tighten the bolts to 5.4 Nm (48 lb in).





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


14. Install the shim to the transaxle case.
15. Install a new bearing outer race into the transaxle case.




16. Using the DT 47521 (1) and a hammer, drive in a new transaxle case oil seal.

The oil seal in depth is 4.3 mm (0.169 in).





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


17. Install the shim to the transaxle case.

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


18. Using the DT 46464 (2) and DT 46465 (1), press in a new outer tapered roller bearing race into the transaxle case.




19. Install the No. 1 transaxle case plate to the transaxle case with the bolt.

Tighten the bolt to 9.8 Nm (87 lb in).




20. Install the differential gear to the transaxle case.




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

Tighten the bolt to 29 Nm (22 lb ft).




23. Using the DT 46461 , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle.





Important: Note down the measured valve.


24. Using the DT 46461 and a small torque wrench, measure the preload of the differential gear.




25. Remove the transaxle housing and install the counter driven gear.




26. Install the transaxle housing and tighten the 16 bolts of the transaxle housing temporarily.
27. Tighten the bolts of the transaxle housing in the same manner as in step 22.

Tighten the bolts to 29 Nm (22 lb in).




28. Using a DT 46461 , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle.




29. Using a DT 46461 and a small torque wrench, measure the preload of the differential gear. From this valve deduct the valve measured in step 24. This is the preload of the counter driven gear.

* The preload for a new bearing is 0.33-0.76 Nm (3.21-6.77 lb in).
* The preload for a used bearing is 0.17-0.38 Nm (1.48-3.39 lb in).





Important: When the preload is larger than the specification, select a thinner adjuster shim. When the preload is smaller than specification, select a thicker adjuster shim.


If the preload of the counter driven gear does not satisfy the specification, select the adjuster shim from the table below and re-measure the valve. Until the valve is within the specification, repeat the procedure.


30. Using the vernier calipers, measure the free length of the 1st and reverse brake piston return spring together with the spring seat.

The standard free length is 18.053 mm (0.71075 in).





Important: If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.


Important: Before assembling the new discs, soak them in ATF for at least 15 minutes.


31. Check to see if the sliding surface of the disc, plate and the flange of the 1st and reverse brake are worn or burnt. Replace them, if necessary.




32. Coat 2 new O-rings (1) with ATF, install them to the 1st and reverse piston.





Important: Be careful not to damage the O-rings of the 1st and reverse brake piston.


33. Install the 1st and reverse brake piston to the transaxle case.




34. Install the return spring to the transaxle case.




35. Install the 4 plates, 4 discs and flange.
36. Install in order: 2-1-2-1-2-1-2-1-3, 3=Plate, 1=Disc, 2=Flange.





Important: Make sure that the snap ring is installed in the groove of the transaxle case correctly.


37. Using the DT 46457 (2) and DT 46455 (1) install the snap ring.





Important: If the piston stroke is non-standard, inspect the discs, plates and flange. The piston stroke is 0.6-1.3 mm (0.024-0.051 in).


38. Using a dial indicator, measure the 1st and reverse brake piston stroke while applying and releasing 392-785 kPa (57-114 psi) of compressed air through port (1).





Important: Be careful not to apply excessive force to the transaxle case.


39. Using the DT 46460 (3), DT 46455 (2) and DT 46456 (1), install the counter drive gear.




40. Coat a new oil seal with ATF.
41. Install the oil seal to the transaxle case.

The oil seal in depth (a) is 0.75-1.25 mm (0.3802-0.3998 in).




42. Install the parking lock rod to the manual valve lever.




43. Install a new spacer to the manual valve lever.




44. Install the manual valve lever shaft and manual valve lever.
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