Manual Transmission - Y4M

Document ID: 1292047
2009 Chevrolet Aveo
Page 1 of 1
| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Transmission | Manual Transmission - Y4M |
Component Locator | Document ID: 1292047
Gear Shift Control
(1) Gear Shift Control Lever Knob

(2) Gear Shift Control Lever Assembly
(3) Select and Shift Cable
2010 General Motors Corporation. All rights reserved.
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7/6/2010
2009 Chevrolet Aveo
Page 1 of 2
Input Shaft and Counter Shaft Gear
(1)
Input Shaft Circlip
(2)
5th Gear Synchronizer Plate
(3)
5th Gear Synchronizer Sleeve
(4)
5th Gear Synchronizer Spring
(5)
5th Gear Synchronizer Key
(6)
5th Gear Synchronizer Hub
(7)
5th Gear Synchronizer Ring
(7-1) Wave Spring

(8)
Input Shaft 5th Gear
(9)
Input Shaft 5th Gear Bearing
(10) Input Shaft 5th Gear Spacer

7/6/2010
Page 2 of 2
(11) Input Shaft Bearing - Left

(12) Input Shaft 4th Gear
(13) 4th Gear Synchronizer Ring
(13-1) Wave Spring
(14) Input Shaft 4th Gear Bearing
(15) 3rd-4th Gear Synchronizer Sleeve
(16) 3rd-4th Gear Synchronizer Spring
(17) 3rd-4th Gear Synchronizer Key
(18) 3rd-4th Gear Synchronizer Hub
(19) 3rd Gear Synchronizer Ring
(20) Input Shaft 3rd Gear
(21) Input Shaft 3rd Gear Bearing
(22) Input Shaft
(23) Input Shaft Bearing - Right
(24) Input Shaft Oil Seal
(25) Reverse Gear Shaft Bolt
(26) Reverse Gear Shaft
(27) Reverse Idle Gear
(28) Counter Shaft Nut
(29) Counter Shaft 5th Gear
(30) Counter Shaft Bearing Shim
(31) Counter Shaft Bearing - Left
(32) Counter Shaft 4th Gear
(33) Counter Shaft 3rd-4th Gear Spacer
(34) Counter Shaft 3rd Gear
(35) Counter Shaft 2nd Gear
(36) 2nd Gear Synchronizer Ring
(37) Counter Shaft 2nd Gear Bearing
(38) 1st-2nd Gear Synchronizer Circlip
(39) 1st-2nd Gear Synchronizer Sleeve
(40) 1st-2nd Gear Synchronizer Spring
(41) 1st-2nd Gear Synchronizer Key
(42) 1st-2nd Gear Synchronizer Hub
(43) 1st Gear Synchronizer Ring
(44) Counter Shaft 1st Gear
(45) Counter Shaft 1st Gear Bearing
(46) Counter Shaft
(47) Counter Shaft Bearing - Right
7/6/2010
2009 Chevrolet Aveo
Page 1 of 2
Gear Shift Fork
(1) Shift Interlock Bolt

(2) Shift and Select Shaft
(3) Shift Lever
(4) Bracket
(5) Low Speed Shift Fork
(6) Low Speed Shift Shaft
(7) Low Speed Shift Shaft Spring/Ball
(8) Low Speed Shift York
(9) High Speed Shift York
(10) High Speed Shaft Spring/Ball
(11) High Speed Shift Shaft
(12) High Speed Shift Fork
(13) Reverse Shift Arm
(14) 5th/Reverse Shift Ball
(15) 5th/Reverse Shift Shaft Spring/Ball
(16) Reverse Shift Shaft Guide Spring/Ball
(17) 5th/Reverse Shift Shaft
(18) 5th/Reverse Shift York
7/6/2010
Page 2 of 2
(19) 5th/Shift Fork Guide Ball

(20) 5th/Shift Fork
(21) Reverse Shift Lever
7/6/2010
2009 Chevrolet Aveo
Page 1 of 2
Differential and Case
(1) Transaxle Case - Right

(2) Speedometer Driven Gear (Vehicle Speed Sensor)
(3) Back Up Light Switch
(4) Transaxle Case - Left
(5) Oil Gutter
(6) Left Case Plate
(7) Side Cover
(8) Differential Ring Gear
(9) Differential Oil Seal - Left
(10) Differential Bearing - Left
(11) Differential Case
(12) Speedometer Drive Gear
(13) Differential Bearing - Right
(14) Differential Oil Seal - Right
(15) Differential Pinion Gear Shaft Pin
(16) Differential Side Gear Adjust Shim
(17) Differential Side Gear
(18) Differential Pinion Gear Shaft
7/6/2010
Page 2 of 2
(19) Differential Pinion Gear

(20) Differential Pinion Gear Washer
7/6/2010
2009 Chevrolet Aveo
Page 1 of 5
Repair Instructions - On Vehicle | Document ID: 2095661
Shift Control Cable Replacement

Removal Procedure
1. Remove the air hose between the air cleaner and throttle body.
Warning: Refer to Batteries Produce Explosive Gases Warning in the Preface section.
2.
3.
4.
5.
6.
Remove the battery from the vehicle.

Remove the transaxle side select and shift control cable pins (1) and the washers (2).
Disconnect the select and shift control cable (3).
Remove the cable E-rings (4).
Disconnect the cables from the cable bracket.
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Page 2 of 5
7. Remove the floor console. Refer to Front Floor Console Replacement.

8. Move the floor carpet to gain access to the gear shift cable.
9.
10.
11.
12.
13.
14.
Remove the gear shift lever side select and shift control cable U-clip.
Remove the eye ring.
Remove the select control cable E-ring.
Disconnect the select control cable.
Remove the shift control cable pin and cable E-ring.
Remove the shift control cable.
Page 3 of 5
15. Remove the select and shift control cable nuts and pull the cables out in the passenger room.
Installation Procedure
1. Install the cables toward the engine compartment through the dash panel.
2. Position the cables on the select and the shift lever.
Page 4 of 5
3. Connect the transaxle side select and shift control cables (4).
4. Connect the gear shift lever side shift control cable.
5.
6.
7.
8.
Insert the gear shift select control cable eye ring to the select arm pin.
Install the gear shift selector lever control cable clip.
Install the gear shift select control cable to the gear shift lever bracket with the E-ring.
Insert a screwdriver to the select arm adjustment hole to prevent the movement of the gear
shift lever in NEUTRAL.
9. Connect the gear shift lever side select control cable.
Page 5 of 5
10. Install the floor console. Refer to Front Floor Console Replacement.
Caution: Refer to Fastener Caution in the Preface section.
11. Install the gear cable adjust nut and tighten to 10 Nm (89 lb in).
12. Install the battery.
13. Install the air hose to the air cleaner and throttle body.
2009 Chevrolet Aveo
Page 1 of 2
Speedometer Driven Gear Replacement

Removal Procedure
1. Disconnect the vehicle speed sensor (VSS) connector (1).

Warning: In order to avoid being burned, do not service the exhaust system while it is still
hot. Service the system when it is cool.
2. Remove the bolt and the speedometer driven gear assembly.
3. Remove the VSS (1) from the speedometer driven gear (2).
Inspection Procedure
1.
2.
3.
4.
Page 2 of 2
Remove the O-ring (2) from the speedometer driven gear housing.
Remove the driven gear pin (1) and disconnect the driven gear (3).
Inspect for a damaged or torn O-ring.
Inspect for a worn or damaged tooth on the driven gear.
1. Install the speedometer driven gear assembly (2) to the transaxle housing mounting bolt and
tighten to 7 Nm (62 lb in).
2. Connect the VSS connector.
2009 Chevrolet Aveo
Page 1 of 2
Gearshift Control Lever Replacement

Removal Procedure
1. Remove the floor console. Refer to Front Floor Console Replacement.

2. Disconnect the select and shift control cable. Refer to Shift Control Cable Replacement.
3. Remove the gear shift control lever bolts (1) and assembly.
1.
2.
3.
4.
Page 2 of 2
Install the gear shift control lever assembly and bolts (1) and tighten to 6 Nm (53 lb in).
Adjust the select cables. Refer to Shift Control Cable Replacement.
Connect the select and shift control cable. Refer to Shift Control Cable Replacement.
Install the floor console. Refer to Front Floor Console Replacement.
2009 Chevrolet Aveo
Page 1 of 16
Transmission Replacement
Special Tools
J 28467-B (DW 117) Universal Engine Support Fixture
Removal Procedure
1. Remove the air cleaner assembly.

2.
3.
4.
5.
6.
7.
Remove the battery and battery tray from the vehicle.

Remove the shift cable pins (2).
Remove the washers (3).
Disconnect the select and the shift cable (4).
Remove the cable E-rings (1).
Disconnect the shift cables from the cable bracket.
8.
9.
10.
11.
Remove the engine wiring harness bending strap.

Remove the ground wire bolt (2).
Disconnect the ground wire (1).
Disconnect the backup lamp switch connector (3).
12.
13.
14.
15.
Remove the radiator lower hose bolts (1).

Disconnect the radiator lower hose (2).
Remove the crankshaft position (CKP) sensor bolt (3).
Disconnect the CKP sensor connector and remove the CKP sensor.
Page 2 of 16
Page 3 of 16
16. Disconnect the vehicle speed sensor (VSS) connector.

17. Remove the VSS.
18. Remove the starter motor.
Warning: While engine is operating, the exhaust system will become extremely hot. To
prevent burns avoid contacting a hot exhaust system.
19. Install J 28467-B (1).
Page 4 of 16
20. Remove the transaxle upper exhaust manifold side bolt (1) and the thermostat housing side
bolt (2).
21.
22.
23.
24.
Drain the transaxle fluid.

Remove the cable adjust nut (1).
Disconnect the cable from the wire clip.
Disconnect the clutch cable from the transaxle mount hole (2).
Page 5 of 16
25. Remove the front under longitudinal frames and stabilizer. Refer to Stabilizer Shaft
Replacement.
26. Remove the drive axle, only from the transaxle side. Refer to Front Drive Axle Inner Shaft
Replacement.
27. Remove the clutch housing lower plate bolts (1) and lower plate (2).
Warning: While engine is operating, the exhaust system will become extremely hot. To
prevent burns avoid contacting a hot exhaust system.
28. Remove the front exhaust pipe nuts from the exhaust manifold side.
29. Remove the gasket and separate the exhaust manifold pipe.
30. Remove the front exhaust pipe.
Page 6 of 16
31. Remove the transaxle mounting bracket bolts.
32. Support the transaxle with a transaxle support jack.
Page 7 of 16
33. Remove the damping block connection nut and bolt (2).
34. Remove the rear mounting bracket bolts (1).
35. Remove the rear mounting bracket from the transaxle.
36. Remove the rear damping block retaining bolts.

37. Remove the rear damping block.
Page 8 of 16
38. Remove the transaxle lower bolts (1, 2).
Caution: Support the engine in the normal position when removing the transaxle. Damage
to related parts can occur.
39. Remove the transaxle.
40. Slide the transaxle sideways from the engine block.
41. Lower the transaxle.
Page 9 of 16
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.
3. Install the transaxle lower bolts (1, 2) and tighten to 60 Nm (44 lb ft).
Page 10 of 16
4. Install the rear damping block retaining bolts and tighten to 55 Nm (41 lb ft).
5. Install the bracket.

6. Install the rear mounting bracket bolts (1) and tighten to 60 Nm (44 lb ft).
7. Install the damping block connection nut and tighten to 82 Nm (61 lb ft).
Page 11 of 16
8. Install the rear transaxle mounting bracket bolts and tighten to 50 Nm (37 lb ft).
9. Install the front exhaust pipe nuts and tighten to 30 Nm (22 lb ft).
10.
11.
12.
13.
Page 12 of 16
Install the clutch housing lower plate (2).

Install the clutch housing lower plate bolts (1) and tighten to 10 Nm (89 lb in).
Install the drive axle. Refer to Front Drive Axle Inner Shaft Replacement.
Install the front under longitudinal frames and stabilizer. Refer to Stabilizer Shaft
Replacement.
14. Install the clutch cable to the transaxle mount (2).

15. Install the cable to the wire clip (1).
16. Install the clutch cable adjusting nut (3).
Page 13 of 16
17. Install the transaxle upper bolts (1, 2) and tighten to 60 Nm (44 lb ft).
18. Install the starter motor. Refer to Starter Replacement.

19. Remove J 28467-B (1).
Page 14 of 16
20. Install the VSS.

21. Install the VSS mounting bolt and tighten to 6 Nm (53 lb in).
22. Connect the VSS connector.
23. Install the radiator lower hose.

24. Install the lower radiator hose bolt and tighten to 12 Nm (106 lb in).
25. Install the CKP sensor and bolt (3) and tighten to 7 Nm (62 lb in)
Page 15 of 16
26. Connect the ground wire (1) and the backup lamp switch connector (3).
27. Install the engine wiring harness bending strap.
28. Install the engine wiring harness bending strap bolt and tighten to 13 Nm (10 lb ft).
29.
30.
31.
32.
33.
Connect the shift cables to the cable bracket.

Install the cable E-rings (1).
Connect the select and shift cable (4).
Install the washers (3).
Install the shift cable pins (2).
Page 16 of 16
34. Install the drain plug (2) and tighten to 28 Nm (21 lb ft).
35. Remove the oil level plug (1).
36. Fill recommended fluid to the proper level.
Specification
The classification is 75W-85 (GL-4).
The capacity is 2.1 liters (2.21 quarts).
37. Install the oil level plug (1) and tighten to 28 Nm (21 lb ft).
38. Install the air cleaner assembly.
39. Adjust the clutch cable.
40. Install the battery and battery tray in the vehicle.
2009 Chevrolet Aveo
Page 1 of 1
Specifications | Document ID: 1397405
Fastener Tightening Specifications

Specification
Application
Metric
English
5th/Reverse Gear Shift Shaft Bolt
13 Nm
10 lb ft
Back Up Light Switch Nut
17 Nm
13 lb ft
Counter Shaft 5th Gear Nut
70 Nm
52 lb ft
7 Nm
62 lb in
Differential Ring Gear Bolt
90 Nm
66 lb ft
Engine Mounting Rear Damping Bolts
55 Nm
41 lb ft
Front Exhaust Pipe Nut - Exhaust Manifold Side/Muffler Side
30 Nm
22 lb ft
6 Nm
53 lb in
Ground Wire Bolt
13 Nm
10 lb ft
High Speed Shift Shaft Bolt - 5th Gear Shift
13 Nm
10 lb ft
Low Speed Shift Shaft Bolt - 3rd and 4th Gear Shift
13 Nm
10 lb ft
Oil Drain Plug
28 Nm
21 lb ft
Oil Level Plug
28 Nm
21 lb ft
Radiator Lower Hose Bracket Bolts
12 Nm
106 lb in
Rear Damping Block Connection Nut and Bolt
82 Nm
61 lb ft
Reverse Idle Gear Shaft Bolt
23 Nm
17 lb ft
Reverse Shift Lever Bolt
23 Nm
17 lb ft
Select Cable Nut - Shift Lever Side
10 Nm
89 lb in
Side Cover - Clutch Plate
10 Nm
89 lb in
Side Cover Bolt
10 Nm
89 lb in
7 Nm
62 lb in
23 Nm
17 lb ft
7 Nm
62 lb in
Transaxle Lower Bolt
60 Nm
44 lb ft
Transaxle Mounting Bolt - Rear Bracket
50 Nm
37 lb ft
Transaxle Mounting Bolts - Rear Damping Block
55 Nm
41 lb ft
Transaxle Upper Bolt - Engine Side
60 Nm
44 lb ft
Crankshaft Position Sensor Bolt
Gear Shift Lever Bolts
Side Cover Plate Bolt

Shift Interlock Bolt
Speedometer Driven Gear Bolt
2009 Chevrolet Aveo
Page 1 of 3
Specifications | Document ID: 1397407
Manual Transmission Specifications

Table 1:
General Specifications
Table 2:
Performance - Manual Transmission
Table 3:
Manual Transmission
Table 4:
Transaxle Case Surface and Bearing Outer Races Clearance Table
Table 5:
Side Gear Axle Direction Play Table
General Specifications
Specification
Application
Metric
English
General
l
Type - Forward Gear
Synchronized Mesh Type
Type - Reverse Gear
Sliding Mesh Type
Gear Ratio - 1st
3.417
Gear Ratio - 2nd
1.950
Gear Ratio - 3rd
1.280
Gear Ratio - 4th
0.971
Gear Ratio - 5th
0.758
Gear Ratio - Reverse
3.273
Final Drive Ratio
4.105
Fluid Capacity
Fluid Classification
2.1 L
2.21 qt
75W-85
GL-4
Service
l
Clearance Between Gear and Synchronizer Ring - Limit
0.5 mm
0.020 in
Clearance Between Gear and Synchronizer Ring - Standard
1.0 mm
0.039 in
Clearance Between Sleeve and Shift Fork - Limit
1.0 mm
0.039 in
Clearance Between Sleeve and Shift Fork - Standard
0.2-0.6 mm
0.0080.024 in
Key Groove Width of Synchronizer Ring - Limit - 1st Gear
10.0 mm
0.394 in
Key Groove Width of Synchronizer Ring - Standard 1st Gear
9.6 mm
0.378 in
Key Groove Width of Synchronizer Ring - Limit - 2nd, 3rd,

4th Gear
10 mm
0.394 in
Key Groove Width of Synchronizer Ring - Standard - 2nd,

3rd, 4th Gear
9.6 mm
0.378 in
Key Groove Width of Synchronizer Ring - Limit - 5th Gear
9.8 mm
0.386 in
Key Groove Width of Synchronizer Ring - Standard 5th Gear
9.4 mm
0.370 in
Shift Fork End Thickness for Low Speed Shift Fork - Limit 1st-2nd Gear
8.1 mm
0.319 in
Shift Fork End Thickness

forGeneral
Low Speed
Shift Fork -All rights reserved.
2010
Motors Corporation.
Page 2 of 3
Standard - 1st-2nd Gear
8.7 mm
0.343 in
Shift Fork End Thickness for Low Speed Shift Fork - Limit 3rd-4th Gear
7.2 mm
0.283 in
Shift Fork End Thickness for High Speed Shift Fork Standard - 3rd-4th Gear
7.8 mm
0.307 in
Shift Fork End Thickness for Low Speed Shift Fork - Limit 5th Gear
7.2 mm
0.283 in
Shift Fork End Thickness for Shift Fork - Standard 5th Gear
7.8 mm
0.307 in
Speedometer Gear Ratio - Driven/Drive
17/18
0.944
Thrust Free Play of Differential Side Gear
0.050.33 mm
0.0020.013 in
Performance - Manual Transmission

Specification
Application
Metric
English
Gradeability
0.4 (tan O)
Maximum Speed
Minimum Turning Radius
153 km/h
95.1 mph
4.8 m
15.7 ft
Manual Transmission
Specification
Application
Metric
Final Drive Ratio
English
4.105:1
Gear Ratio
l
1st
3.417:1
2nd
1.950:1
3rd
1.280:1
4th
0.971:1
5th
0.758:1
Reverse
3.273:1
Maker
DWMC
Oil Capacity
2.1 L
Type or Model
2.21 qt
Y4M
Transaxle Case Surface and Bearing Outer Races Clearance Table

Measured value
Shim thickness
0.33-0.37 mm (0.0130-0.0146 in)
0.45 mm (0.0177 in)
0.38-0.42 mm (0.0147-0.0165 in)
0.50 mm (0.0197 in)
0.43-0.47 mm (0.0169-0.0185 in)
0.55 mm (0.0217 in)
0.48-0.52 mm (0.0189-0.0205 in)
0.60 mm (0.0236 in)
0.53-0.57 mm (0.0209-0.0224 in)
0.65 mm (0.0256 in)
0.58-0.62 mm (0.0228-0.0244 in)
0.70 mm (0.0276 in)
0.63-0.67 mm (0.0248-0.0264 in)
0.75 mm (0.0295 in)
Page 3 of 3
0.68-0.72 mm (0.0268-0.0283 in)
0.80 mm (0.0315 in)
0.73-0.77 mm (0.0287- 0.0303 in)
0.85 mm (0.0335 in)
0.78-0.82 mm (0.0307-0.0323 in)
0.90 mm (0.0354 in)
0.83-0.87 mm (0.0327-0.0343 in)
0.90 mm (0.0354 in)
0.88-0.92 mm (0.0346-0.0362 in)
1.00 mm (0.0394 in)
0.93-0.97 mm (0.0366-0.0382 in)
1.05 mm (0.0413 in)
0.98-1.02 mm (0.0386-0.0402 in)
1.10 mm (0.0433 in)
1.03-1.07 mm (0.0406-0.0421 in)
1.15 mm (0.0453 in)
Side Gear Axle Direction Play Table

Specification
Application
Thrust Adjusting Shim
Thrust Free Play of Differential Side
Metric
English
0.90-0.95 mm
0.0354-0.0374 in
1.00-1.05 mm
0.0394-0.0413 in
1.10-1.15 mm
0.0433-0.0453 in
1.20 mm
0.0472 in
0.05-0.33 mm
0.0020-0.0130 in

Manual Transmission - Y4M

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Document ID: 1292047

2009 Chevrolet Aveo

Gear Shift Control

(1) Gear Shift Control Lever Knob

2010 General Motors Corporation. All rights reserved.

Document ID: 1225775

2009 Chevrolet Aveo

Input Shaft and Counter Shaft Gear

Input Shaft Circlip

5th Gear Synchronizer Plate

5th Gear Synchronizer Sleeve

5th Gear Synchronizer Spring

5th Gear Synchronizer Key

5th Gear Synchronizer Hub

5th Gear Synchronizer Ring

(7-1) Wave Spring

Input Shaft 5th Gear

Input Shaft 5th Gear Bearing

(10) Input Shaft 5th Gear Spacer

Document ID: 1225775

(11) Input Shaft Bearing - Left

Document ID: 1292048

2009 Chevrolet Aveo

Gear Shift Fork

(1) Shift Interlock Bolt

2010 General Motors Corporation. All rights reserved.

Document ID: 1292048

(19) 5th/Shift Fork Guide Ball

Document ID: 1292049

2009 Chevrolet Aveo

Differential and Case

(1) Transaxle Case - Right

2010 General Motors Corporation. All rights reserved.

Document ID: 1292049

(19) Differential Pinion Gear

Document ID: 2095661

2009 Chevrolet Aveo

Shift Control Cable Replacement

Remove the battery from the vehicle.

2010 General Motors Corporation. All rights reserved.

Document ID: 2095661

7. Remove the floor console. Refer to Front Floor Console Replacement.

Document ID: 2095661

Document ID: 2095661

Document ID: 2095661

Document ID: 2095663

2009 Chevrolet Aveo

Speedometer Driven Gear Replacement

1. Disconnect the vehicle speed sensor (VSS) connector (1).

2010 General Motors Corporation. All rights reserved.

Document ID: 2095663

Document ID: 2095665

2009 Chevrolet Aveo

Gearshift Control Lever Replacement

1. Remove the floor console. Refer to Front Floor Console Replacement.

2010 General Motors Corporation. All rights reserved.

Document ID: 2095665

Document ID: 2095668

2009 Chevrolet Aveo

1. Remove the air cleaner assembly.

Remove the battery and battery tray from the vehicle.

2010 General Motors Corporation. All rights reserved.

Document ID: 2095668

Remove the engine wiring harness bending strap.