GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Aveo 🢒 Transmission/Transaxle 🢒 Manual Transmission - MTN 🢒 Transmission Disassemble

    Object Number: 956228 Size: SH
  1. Remove the filler plug and gasket.

    2. Object Number: 956234 Size: SH
  2. Remove the drain plug and gasket.

    3. Object Number: 956237 Size: SH
  3. Remove the bolt and speedometer drive hole cover.

    4. Object Number: 956253 Size: SH
  4. Remove the backup light switch and gasket from the transaxle case.

    5. Object Number: 956261 Size: SH
  5. Remove the 3 bolts and the control cable bracket.

    6. Object Number: 956267 Size: SH
  6. Remove the 2 bolts and the selecting bellcrank assembly.
  7. Install the guide bushing (1) in the shift lever.

    8. Object Number: 956273 Size: SH
  8. Remove the lock ball assembly from the transaxle case.

    9. Object Number: 956278 Size: SH
  9. Remove the 4 bolts (1) and the select lever shaft assembly from the transaxle case.

    10. Object Number: 956285 Size: SH
  10. Remove the 9 transmission case cover bolts.

    11. Object Number: 956291 Size: SH
  11. Using a brass bar and hammer, carefully tap on the tabs of the transmission case cover to remove the cover from the transmission case.

    12. Object Number: 956308 Size: SH
  12. Using a dial indicator, measure the thrust clearance of 6th gear.

    13. Thrust Clearance
    Standard thrust clearance should be between 0.10-0.60 mm (0.0039-0.0236 in). Maximum clearance should not exceed 0.60 mm (0.0236 in).


    Object Number: 956314 Size: SH
  13. Using a dial indicator, measure the radial runout of 6th gear.

    14. Thrust Clearance
    Standard radial runout should be between 0.009-0.50 mm (0.0003-0.0020 in). Maximum runout should not exceed 0.50 mm (0.0020 in).

  14. If the gear exceeds any of the maximum measurements, replace the gear, roller bearing or shaft.

    15. Object Number: 956317 Size: SH
  15. Remove the 6th driven gear snap ring from the output shaft.

    16. Object Number: 956323 Size: SH
  16. Using a 2 jaw puller or equivalent, remove the rear bearing assembly, 6th driven gear from the output shaft.

    17. Object Number: 956329 Size: SH
  17. Remove the spacer from the output shaft.

    18. Object Number: 956331 Size: SH
  18. Remove the input shaft snap ring.

    19. Object Number: 956332 Size: SH
  19. Using a 2 jaw puller or equivalent, remove the rear bearing assembly, 6th driven gear from the input shaft.

    20. Object Number: 956336 Size: SH
  20. Remove the roller bearing and spacer from the input shaft.

    21. Object Number: 1594195 Size: SH
  21. Install the 5th driven gear puller DT-47947 as shown.

    22. Object Number: 1594194 Size: SH
  22. Install the harmonic balancer puller J-24420-C to DT-47947, then remove the 5th driven gear from the transaxle assembly.

    23. Object Number: 1594200 Size: SH
  23. Using the bolts from DT-47947 and harmonic balancer puller J-24420-C, remove the synchronizer hub from the transaxle assembly.

    24. Object Number: 956338 Size: SH
  24. Remove the 6th gear synchronizer ring.

    25. Object Number: 956342 Size: SH
  25. Remove the bolt, No.3 gear shift fork and No.3 hub sleeve.

    26. Object Number: 956348 Size: SH
  26. Using a dial indicator, measure the thrust clearance of 5th gear.

    27. Thrust Clearance
    Standard thrust clearance should be between 0.10-0.62 mm (0.0039-0.0244 in). Maximum clearance should not exceed 0.62 mm (0.0244 in).


    Object Number: 956349 Size: SH
  27. Using a dial indicator, measure the radial runout of 6th gear.

    28. Thrust Clearance
    Standard radial runout should be between 0.015-0.056 mm (0.0006-0.0022 in). Maximum runout should not exceed 0.56 mm (0.0022 in).

  28. If the gear exceeds any of the maximum measurements, replace the gear, roller bearing or shaft.

    29. Object Number: 956350 Size: SH
  29. Remove the 5th gear snap ring from the shaft.

    30. Object Number: 957836 Size: SH
  30. Using a puller, remove the No.3 clutch hub assembly.

    31. Object Number: 958727 Size: SH
  31. Remove 5th gear and the 5th gear synchronizer ring from the input shaft.

    32. Object Number: 958758 Size: SH
  32. Remove the snap ring from the output shaft.

    33. Object Number: 958841 Size: SH
  33. Remove the roller bearing and 2 spacers.

    34. Object Number: 958859 Size: SH
  34. Using a puller, remove the 5th driven gear.

    35. Object Number: 958922 Size: SH
  35. Remove the 5 rear bearing retainer bolts.
  36. Remove the rear bearing retainer from the transaxle case.

    37. Object Number: 958952 Size: SH
  37. Using snap ring pliers or equivalent, remove the 2 snap rings.

    38. Object Number: 958960 Size: SH
  38. Remove the reverse idler gear shaft lock bolt and gasket from the transaxle case.

    39. Object Number: 959007 Size: SH
  39. Remove the snap ring from the No.2 shift fork shaft.

    40. Object Number: 959072 Size: SH
  40. Using a Allen wrench or equivalent, remove the 3 screw plug assemblies from the transaxle case

    41. Object Number: 959157 Size: SH
  41. Using a Allen wrench or equivalent, remove the 2 screw plugs from the transaxle case

    42. Object Number: 959262 Size: SH
  42. Remove the 3 transmission case retaining bolts.

    43. Object Number: 959264 Size: SH
  43. Remove the 13 transaxle case retaining bolts.

    44. Object Number: 959266 Size: SH
  44. Using a brass bar and hammer, carefully tap the tabs on the case in order to separate the case halves.

    45. Object Number: 959312 Size: SH
  45. Remove the 2 bolts and the oil receiver pipes from the transaxle case.

    46. Object Number: 959477 Size: SH
  46. Remove the 2 reverse shift arm bracket retaining bolts, then remove the bracket.

    47. Object Number: 959575 Size: SH
  47. Remove the reverse idler gear, thrust washer and shaft.

    48. Object Number: 959608 Size: SH
  48. Remove the 2 snap rings from the No.1 and No.2 gear shift fork shafts.

    49. Object Number: 959640 Size: SH
  49. Remove the 3 gear shift fork set bolts.

    50. Object Number: 1162528 Size: SH
  50. Remove the No.2 gear shift fork shaft from the No.2 gear shift fork.
  51. Remove the No.1 gear shift head, No.1 gear shift fork and the reverse shift fork from the transaxle case.

    52. Object Number: 959675 Size: SH
  52. Remove the No.1 gear shift fork shaft from the No.1 gear shift fork from the transaxle case.

    53. Object Number: 959686 Size: SH
  53. Remove the No.1 gear shift head from the shift shaft.

    54. Object Number: 959693 Size: SH
  54. Remove the No.1 gear shift fork from the reverse gear assembly.

    55. Object Number: 959728 Size: SH
  55. Remove the No.3 gear shift fork shaft from the reverse shift fork from the transaxle case.
  56. Remove the reverse shift fork.

    57. Object Number: 959734 Size: SH
  57. Remove the No.2 gear shift fork from the No.2 hub sleeve groove.

    58. Object Number: 959739 Size: SH
  58. Remove the input and output shafts together from the transaxle case.

    59. Object Number: 959747 Size: SH
  59. Remove the differential case assembly from the transaxle case.

    60. Object Number: 959753 Size: SH
  60. Remove the magnet from the transaxle case.

    61. Object Number: 959759 Size: SH
  61. Disassemble the No.3 clutch hub assembly.

    62. Object Number: 959775 Size: SH
  62. Check the 5th and 6th gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.

    63. Object Number: 959788 Size: SH
  63. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.75 mm (0.0295 in). If the clearance is less than the minimum, replace the synchronizer ring.

    64. Object Number: 959791 Size: SH
  64. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.89 mm (0.0350 in). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.

    65. Object Number: 959840 Size: SH
  65. Remove the bolt and the transaxle case receiver from the transaxle case.

    66. Object Number: 959879 Size: SH
  66. If necessary, remove the input shaft bearing.

    67. Object Number: 959891 Size: SH
  67. If the input shaft bearing has been removed, remove the oil seal.

    68. Object Number: 959935 Size: SH
  68. If the output shaft front bearing requires replacement, remove the bolt and output shaft cover.

    69. Object Number: 959966 Size: SH
  69. Using a puller, remove the output shaft front bearing.

    70. Object Number: 960243 Size: SH
  70. Using a feeler gage, measure the thrust clearance for 3rd and 4th gears of the input shaft.

    71. Standard Clearance
    3rd gear: 0.10-0.35 mm (0.0039-0.0138 in). 4th gear: 0.10-0.55 mm (0.0039-0.0217 in).


    Object Number: 960279 Size: SH
  71. Using a dial indicator, measure the radial clearance between the gears and the shaft.

    72. Standard Clearance
    3rd and 4th gear radial clearance: 0.15-0.58 mm (0.0006-0.0023 in).

  72. If the clearance exceeds the maximum measurement, replace the gear, roller bearing or shaft.

    73. Object Number: 960283 Size: SH
  73. Remove the input shaft snap ring.

    74. Object Number: 960289 Size: SH
  74. Using a press, remove the center ball bearing and 4th gear from the input shaft.

    75. Object Number: 960292 Size: SH
  75. Remove the roller bearing and spacer from the input shaft.

    76. Object Number: 960294 Size: SH
  76. Remove the 4th gear synchronizer ring from the input shaft.

    77. Object Number: 960300 Size: SH
  77. Remove the No.2 hub sleeve snap ring.

    78. Object Number: 960303 Size: SH
  78. Using a press, remove the No.2 hub sleeve and 3rd gear from the input shaft.

    79. Object Number: 1132073 Size: SH
  79. Remove the No.2 3rd gear synchronizer ring.

    80. Object Number: 960470 Size: SH
  80. Remove the roller bearing from the input shaft.

    81. Object Number: 960478 Size: SH
  81. Disassemble the No.2 hub sleeve assembly.

    82. Object Number: 959775 Size: SH
  82. Check the 3rd and 4th gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.

    83. Object Number: 959788 Size: SH
  83. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. 3rd gear minimum clearance is 0.65 mm (0.0256 in). 4th gear minimum clearance is 0.75 mm (0.0295 in). If the clearance is less than the minimum, replace the synchronizer ring.

    84. Object Number: 960554 Size: SH
  84. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.35 mm (0.014 in). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.

    85. Object Number: 960562 Size: SH
  85. Using a micrometer, measure the outer diameter of the input shaft journal surfaces.

    86. Minimum Outer Diameter

        • A: 21.991 mm (0.8658 in)
        • B: 24.885 mm (0.9797 in)
        • C: 28.985 mm (1.1411 in)
        • D: 30.985 mm (1.2199 in)
        • E: 24.985 mm (0.9837 in)
  86. If the out diameter is less than the minimum, replace the input shaft.

    87. Object Number: 960572 Size: SH
  87. Using a dial indicator, check the output shaft journals for runout. Maximum runout is 0.03 mm (0.0012 in).
  88. If the runout exceeds the maximum, replace the output shaft.

    89. Object Number: 960814 Size: SH
  89. Using a feeler gage, measure the thrust clearance for 1st and 2nd gears of the output shaft.

    90. Standard Clearance
    1st gear: 0.10-0.40 mm (0.0039-0.0157 in). 2nd gear: 0.10-0.55 mm (0.0039-0.0217 in).


    Object Number: 960874 Size: SH
  90. Using a dial indicator, measure the radial clearance between the gears and the shaft.

    91. Standard Clearance
    1st and 2nd gear radial clearance: 0.15-0.58 mm (0.0006-0.0023 in).

  91. If the clearance exceeds the maximum measurement, replace the gear, roller bearing or shaft.

    92. Object Number: 960896 Size: SH
  92. Using a press, remove the radial ball bearing and the 4th driven gear from the output shaft.

    93. Object Number: 960898 Size: SH
  93. Remove the spacer from the output shaft.

    94. Object Number: 960901 Size: SH
  94. Shift the reverse gear into 1st gear.

    95. Object Number: 960905 Size: SH
  95. Using a press, remove the 3rd driven gear and 2nd gear from the output shaft.

    96. Object Number: 960907 Size: SH
  96. Remove the roller bearing from the output shaft

    97. Object Number: 960909 Size: SH
  97. Remove the spacer from the output shaft.

    98. Object Number: 960912 Size: SH
  98. Remove the No.2 synchronizer ring from the output shaft.

    99. Object Number: 960914 Size: SH
  99. Remove the snap ring from the output shaft.

    100. Object Number: 963128 Size: SH
  100. Using a press, remove the reverse gear assembly, 1st gear and the No.1 synchronizer from the output shaft.

    101. Object Number: 963146 Size: SH
  101. Remove the No.1 synchronizer from 1st gear.

    102. Object Number: 963149 Size: SH
  102. Remove the roller bearing from the output shaft.

    103. Object Number: 963155 Size: SH
  103. Remove the 1st gear thrust washer from the output shaft.

    104. Object Number: 963158 Size: SH
  104. Using a magnet, remove the ball from the output shaft.
  105. Remove the snap ring from the output shaft.

    106. Object Number: 963166 Size: SH
  106. Using a press, remove the front bearing inner race.

    107. Object Number: 963167 Size: SH
  107. Disassemble the reverse gear assembly.

    108. Object Number: 963168 Size: SH
  108. Check the 1st gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.

    109. Object Number: 963172 Size: SH
  109. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.75 mm (0.0295 in). If the clearance is less than the minimum, replace the synchronizer ring.

    110. Object Number: 963174 Size: SH
  110. Check the 2nd gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.

    111. Object Number: 963177 Size: SH
  111. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.70 mm (0.0276 in). If the clearance is less than the minimum, replace the synchronizer ring.

    112. Object Number: 963178 Size: SH
  112. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.35 mm (0.014 in). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.

    113. Object Number: 963183 Size: SH
  113. Using a micrometer, measure the outer diameter of the input shaft journal surfaces.

    114. Minimum Outer Diameter

        • 1: 31.985 mm (1.2592 in)
        • 2: 37.985 mm (1.4955 in)
        • 3: 32.985 mm (1.2986 in)
  114. If the out diameter is less than the minimum, replace the output shaft.

    115. Object Number: 960572 Size: SH
  115. Using a dial indicator, check the output shaft journals for runout. Maximum runout is 0.03 mm (0.0012 in).
  116. If the runout exceeds the maximum, replace the output shaft.