Document ID: 1338629 Page 1 of 7

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Transmission |
Automatic Transmission - Aisin 81-40LE | Component Locator | Document ID: 1338629

Disassembled Views
Case and Associated Parts (1 of 2)

(1) Breather Hose

(2) Clip
(3) Breather Plug
(4) O-Ring
(5) Washer
(6) Drain Plug
(7) O-Ring
(8) Bolt Plug
(9) O-Ring
(10) Oil Cooler Inlet Union
(11) O-Ring
(12) Oil Cooler Outlet Union
(13) Input Shaft Speed (ISS) Sensor

Case and Associated Parts (2 of 2)

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(1) Oil Seal

(2) Transaxle Housing
(3) Oil Reservoir Plate
(4) Transaxle Oil Apply Pipe
(5) Spring
(6) Check Valve Pipe Clamp
(7) Governor Apply Gasket
(8) Brake Drum Gasket
(9) Differential Gear Oil Apply Pipe
(10) O-Ring
(11) Transaxle Wire
(12) Torsion Spring
(13) Transaxle Oil Apply Pipe Clamp
(14) Parking Lock Pawl
(15) Manual Valve Lever
(16) Spacer
(17) Oil Seal

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(18) Park/Neutral Position Switch

(19) Lock Washer
(20) Control Lever
(21) Washer
(22) Spring
(23) O-Ring
(24) Overdrive Brake Accumulator Piston
(25) O-Ring
(26) Spring
(27) O-Ring
(28) Forward Clutch Accumulator Piston
(29) O-Ring
(30) O-Ring
(31) Direct Clutch Accumulator Piston
(32) O-Ring
(33) Spring
(34) Manual Detent Spring
(35) Pin
(36) Parking Lock Rod
(37) Parking Lock Pawl Shaft
(38) Manual Valve Lever Shaft
(39) Parking Lock Pawl Bracket
(40) Oil Pan
(41) Gasket
(42) Magnet
(43) Oil Strainer
(44) Gasket
(45) Valve Body

Internal Components

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(1) Planetary Ring Gear

(2) O-Ring
(3) 1st and Reverse Brake Piston
(4) O-Ring
(5) 1st and Reverse Brake Piston Return Spring
(6) Plate
(7) Disc
(8) Flange
(9) Snap Ring
(10) Planetary Gear
(11) Thrust Washer
(12) No. 2 One-Way Clutch
(13) Anti-Rattle Clip
(14) Flange
(15) Disc
(16) Plate
(17) 2nd Brake Piston Return Spring

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(18) O-Ring
(19) 2nd Brake Piston
(20) O-Ring
(21) 2nd Brake Clutch Cylinder
(22) Snap Ring
(23) Thrust Bearing Race
(24) Front Planetary Sun Gear
(25) Thrust Bearing Race
(26) One-Way Clutch Assembly
(27) Thrust Washer
(28) Rear Planetary Sun Gear
(29) Snap Ring
(30) Flange
(31) Disc
(32) Plate
(33) Thrust Bearing Race
(34) Thrust Needle Roller Bearing
(35) Forward Clutch Hub
(36) Thrust Bearing Race
(37) Thrust Needle Roller Bearing
(38) Thrust Bearing Race
(39) Forward and Reverse Clutch Assembly
(40) Thrust Needle Roller Bearing
(41) Snap Ring
(42) O/D Brake Return Spring
(43) O/D Brake Piston
(44) O-Ring
(45) Seal Ring
(46) Transaxle Rear Cover
(47) Governor Apply Gasket
(48) O-Ring
(49) Bolt Plug

Differential and Oil Pump

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(1) Side Bearing Outer Race

(2) Shim
(3) Outer Tapered Roller Bearing Race
(4) Counter Driven Gear
(5) Oil Seal
(6) Transaxle Case Plate
(7) Governor Apply Gasket
(8) Counter Driven Gear
(9) Direct Clutch Hub
(10) Thrust Bearing Race
(11) Direct Clutch Assembly
(12) Thrust Needle Roller Bearing
(13) Differential Case
(14) Oil Pump

Bearing and Race Installation and Direction

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Thrust Bearing
Front Race Diameter Diameter Rear Race Diameter
Mark Inside Outside Inside Outside Inside Outside
32.5 mm 48.5 mm
1 -- -- -- --
(1.280 in) (1.909 in)
17.8 mm 30.2 mm 20.5 mm 32.6 mm
2 -- --
(0.701 in) (1.189 in) (0.807 in) (1.283 in)
19.3 mm 29.0 mm
3 -- -- -- --
(0.760 in) (1.142 in)
42.5 mm 57.5 mm
4 -- -- -- --
(1.673 in) (2.264 in)
34.95 mm 45.50 mm 33.3 mm 46.5 mm
5 -- --
(1.3670 in) (1.7913 in) (1.311 in) (1.831 in)
19.3 mm 30.6 mm 18.1 mm 29.6 mm 18.1 mm 28.2 mm
6
(0.760 in) (1.205 in) (0.713 in) (1.165 in) (0.713 in) (1.110 in)
43.2 mm 62.0 mm
7 -- -- -- --
(1.701 in) (2.441 in)

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Document ID: 1409022 Page 1 of 1

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Transmission |
Automatic Transmission - Aisin 81-40LE | Component Locator | Document ID: 1409022

Shift Select Control

(1) Select Control Lever Assembly

(2) Bolt
(3) Nut
(4) Select Control Cable
(5) Clamp
(6) E-Ring
(7) Cable Fastener
(8) Bolt

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Document ID: 1340192 Page 1 of 7

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Transmission |
Automatic Transmission - Aisin 81-40LE | Visual Identification | Document ID: 1340192

Automatic Transmission Components

During reassembly, please refer to the spring specifications below to help you to
discriminate between the different springs.

Upper Valve Body Spring

Figure 1: Oil Pump

Figure 2: Direct Clutch
Figure 3: Plantery Ring Gear
Figure 4: One-Way Clutch
Figure 5: Forward and Reverse Clutch
Figure 6: Counter Driven Gear
Figure 7: Valve Body
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Figure 8: 2004 M Car RR

Figure 9: Upper Valve Body
Mark Name Color Free Length Outer Diameter Total
Number of
Metric English Metric English Coils
1 3-4 Shift Valve Red 25.5 mm 1.0039 in 9.73 mm 0.3831 in 7.75
2 Lock Up Control Valve Yellow 20.87 mm 0.8217 in 5.55 mm 0.2185 in 11.15
3 Reverse Control Valve -- 25.58 mm 1.0071 in 8.64 mm 0.3402 in 8.75
Secondary Regulator
4 White 34.56 mm 1.3606 in 8.8 mm 0.346 in 12.27
Valve
Reverse Clutch
5 -- 65.4 mm 2.5748 in 17 mm 0.669 in 13.7
Accumulator Piston
2nd Brake
6 Accumulator Piston - White 69 mm 2.7165 in 16 mm 0.63 in 15.1
Outer
2nd Brake
7 Accumulator Piston - -- 45.9 mm 1.8071 in 10.5 mm 0.413 in 16.9
Inner
3-4 Shift Timing
8 Pink 28.41 mm 1.1185 in 6.4 mm 0.252 in 10.49
Valve

Upper Valve Body Key

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Mark Retainer Height Width Thickness

Metric English Metric English Metric English
1 Check Valve 11.5 mm 0.453 in 5 mm 0.197 in 3.2 mm 0.126 in
2 Secondary Regulator Valve 16 mm 0.63 in 5 mm 0.197 in 3.2 mm 0.126 in
3 Lock Up Control Valve 16 mm 0.63 in 5 mm 0.197 in 3.2 mm 0.126 in
4 Reverse Control Valve 11.5 mm 0.453 in 5 mm 0.197 in 3.2 mm 0.126 in

Upper Valve Body Check Ball

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Name Metric English

Check Ball 5.535 mm 0.21791 in
Figure
Lower Valve Body
10:
Figure
Lower Valve Body Spring
11:
Mark Name Color Free Length Outer Diameter Total Number
Metric English Metric English of Coils

4-3 Shift Timing

1 -- 33.95 mm 1.3366 in 8.2 mm 0.323 in 12.5
Valve No. 1
Primary Regulator
2 -- 50.53 mm 1.9894 in 13.6 mm 0.535 in 11.07
Valve
Lock Up Relay
3 Red 23.42 mm 0.9221 in 5.86 mm 0.2307 in 12.25
Valve
Solenoid Modulator
4 Yellow 32.13 mm 1.265 in 8 mm 0.315 in 15.75
Valve
5 1-2 Shift Valve Red 25.5 mm 1.0039 in 9.73 mm 0.3831 in 7.75

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6 2-3 Shift Valve Red 25.5 mm 1.0039 in 9.73 mm 0.3831 in 7.75

Low Modulator
7 -- 30.43 mm 1.198 in 7.75 mm 0.3051 in 12.72
Valve

Lower Valve Body Key

Mark Retainer Height Width Thickness

Metric English Metric English Metric English
1 4-3 Shift Timing Valve No. 1 36 mm 1.417 in 5 mm 0.197 in 3.2 mm 0.126 in
2 2-3 Shift Valve 10 mm 0.394 in 5 mm 0.197 in 3.2 mm 0.126 in
3 1-2 Shift Valve 10 mm 0.394 in 5 mm 0.197 in 3.2 mm 0.126 in
4 Primary Regulator Valve 9.8 mm 0.386 in 5.2 mm 0.205 in 3.2 mm 0.126 in
5 Lock Up Relay Valve 16 mm 0.63 in 5 mm 0.197 in 3.2 mm 0.126 in
6 Solenoid Modulator Valve 24 mm 0.945 in 5 mm 0.197 in 3.2 mm 0.126 in
7 Low Modulator Valve 24 mm 0.945 in 5 mm 0.197 in 3.2 mm 0.126 in

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Differential Case

(1) Differential Pinion Thrust Washer

(2) Differential Pinion Gear
(3) Differential Side Gear Thrust Washer
(4) Differential Side Gear
(5) Pin
(6) Differential Pinion Shaft
(7) Oil Seal
(8) Side Bearing Outer Race
(9) Tapered Roller Bearing
(10) Differential Case
(11) Differential Ring Gear
(12) Tapered Roller Bearing
(13) Side Bearing Outer Race
(14) Shim

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(15) Oil Seal

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