GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Aveo 🢒 Transmission/Transaxle 🢒 Manual Transaxle - Y4M 🢒 Transmission Assemble

Tools Required

    • DT 46496 (DW09940-53111) Gear, Bearing Installer
    • DT 46497 (DW09943-78210) Bushing, Seal Installer
    • DT 46612 (DW09913-76010) Bushing, Seal Installer
    • DT 47515 (DW220-100) Needle Bearing Remover
    • DT 47516 Needle Bearing Installer
    • DT 47517 Input Shaft Holder
    • KM-519 Ring Installer

    Object Number: 1223717 Size: SH

    Important: Use only a new oil seal.

  1. Install the input shaft oil seal using DT 46497  (1).

    2. Important: Coat the transaxle inner parts with gear fluid when installing.

  2. Install the differential right side oil seal using DT 46612 .

    3. Object Number: 1223707 Size: SH
  3. Install the oil plate with the bolts.
  4. Install the oil gutter with the bolt.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the oil level plug, including the steel gasket.

    6. Tighten
    Tighten the oil level plug to 25-30 N·m (18-22 lb ft).

  6. Install the differential left side oil seal using KM-519  (2).

    7. Object Number: 1223722 Size: SH
  7. Install the differential assembly (1) to the right side of the transaxle case. Position the differential ring gear surface lower than the right side of the transaxle case surface.

    8. Object Number: 1223715 Size: SH
  8. Install the low and the high speed shift shaft assembly to the gear unit.

    9. Important: Do NOT damage the teeth of the counter shaft pinion and the differential ring gear.

  9. Push the gear unit by matching the unit with the input and the counter shaft hole (1).

    10. Object Number: 1223705 Size: SH
  10. Install the 5th reverse gear shift shaft.

    11. Important: Match the marking of the reverse idle gear shaft bolt hole with the protrusion of the transaxle case - right side.

  11. Install the reverse idle gear shaft assembly (2).
  12. Install the reverse gear shift lever (1).

    13. Tighten
    Tighten the bolts to 18-28 N·m (13-21 lb ft).


    Object Number: 1223736 Size: SH
  13. Install the 3rd-4th gear shift shaft ball and spring (1).

    14. Tighten
    Tighten the bolt to 10-16 N·m (7-12 lb ft).

    Important: Install the correct gear shift shaft spring that was marked when removing.

  14. Install the 5th reverse gear shift shaft ball and spring (2).

    15. Tighten
    Tighten the bolt to 10-16 N·m (7-12 lb ft).


    Object Number: 1241236 Size: SH
  15. Install the shift and select and shaft needle bearing using DT 47516  (1) with DT 47515  (2).

    16. Object Number: 1240975 Size: SH
  16. Install the gear shift and select shaft assembly.
  17. Install the shift and select shaft oil seal (6).
  18. Install the shift and select bellows (5).
  19. Install the gear select spring assemblies (2).
  20. Install the gear shift interlock plate (9).
  21. Install the gear shift lever (8).
  22. Install the 5th and reverse gear shift cam (3).
  23. Install the return spring (7).
  24. Install the shift and select shaft (4).

    25. Object Number: 1241239 Size: SH

    Important: When installing the inner and outer pins, make the crevices of 2 pins symmetric to each other.

  25. Install the shift and the select lever inner and outer pins.

    26. Object Number: 1291927 Size: SH
  26. Coat the transaxle case with recommended Transaxle Case Sealant-THREE BOND 1215.
  27. Install the transaxle left side case to the transaxle right side case bolts (1).

    28. Tighten
    Tighten the bolts to 15-22 N·m (11-16 lb ft).


    Object Number: 1241240 Size: SH
  28. Install the 1st-2nd gear shift shaft ball and spring using the bolt (1).

    29. Tighten
    Tighten the bolt to 10-16 N·m (7-12 lb ft).

  29. Install the 3rd-4th gear shift shaft ball and spring using the bolt (2).

    30. Tighten
    Tighten the bolt to 10-16 N·m (7-12 lb ft).

  30. Install the reverse idle gear shaft bolt (3).

    31. Tighten
    Tighten the bolt to 18-28 N·m (13-21 lb ft).


    Object Number: 1223704 Size: SH

    Important: Check if the bearing and the outer race are correctly installed by rotating counter shaft.

  31. Install the counter shaft bearing outer race (2) using DT 46496  (1).

    32. Object Number: 1223740 Size: SH
  32. Measure the clearance between the transaxle case surface (3) and the bearing outer race (2) using a straight ruler (1) and a gage. Refer to Manual Transmission Specifications .
  33. Select a shim so that clearance is within standard.

    34. Object Number: 1223739 Size: SH

    Important: Use only new screws.

  34. Install the side cover plate (1).

    35. Tighten
    Tighten the screws to 6-7 N·m (53-62 lb in).

    Important: Position the machined boss side toward the side cover plate.

  35. Install the counter shaft 5th gear (3).

    36. Object Number: 1241241 Size: SH
  36. Push the shift for toward the 5th gear.
  37. Hold the input shaft using DT 47517  (1).

    38. Tighten
    Tighten the gear nut to 60-80 N·m (44-59 lb ft).


    Object Number: 1223684 Size: SH
  38. Insert the input shaft 5th gear bearing into the input shaft.
  39. Install the 5th gear wave spring and synchronizer ring, matching the synchronizer's oil groove and input shaft punched mark (1).

    40. Object Number: 1223734 Size: SH

    Important: When assembling the synchronizer sleeve and hub, ensure distance (a) equals distance (b).

  40. Install the synchronizer springs to hub (1).
  41. Install the synchronizer key (2).
  42. Position the longer boss side of hub toward inner side (3).
  43. Position the chamfered spline of sleeve toward inner side and install the hub to the sleeve (4).

    44. Object Number: 1223748 Size: SH
  44. Install the 5th gear fork to the synchronizer hub assembly.

    45. Important: Position the longer boss side of hub toward inner side and match the synchronizer key and the hub groove with the input shaft punched mark.

  45. Install the 5th gear fork and the synchronizer hub assembly to the input shaft.

    46. Object Number: 1223765 Size: SH
  46. Push the 5th gear shift fork toward the 5th gear.

    47. Important: Use only new shift fork pin.

  47. Install the 5th gear shift fork pin using a pin punch and a hammer (1).

    48. Object Number: 1223761 Size: SH
  48. Install the 5th gear synchronizer plate.
  49. Install the 5th gear snap ring (1).

    50. Important: Use only new snap rings.

  50. Install the 5th gear fork snap ring (2).
  51. Tighten the fork plug after inserting the guide ball into the fork hole.

    52. Object Number: 1223730 Size: SH
  52. Install the side cover (1) with recommended Side Cover Sealant-THREE BOND 1215.

    53. Tighten
    Tighten the bolts to 8-12 N·m (71-106 lb in).


    Object Number: 1240927 Size: SH
  53. Install the shift interlock bolt.

    54. Tighten
    Tighten the bolt to 18-28 N·m (13-21 lb ft).


    Object Number: 1223764 Size: SH
  54. Install the backup light switch (1).

    55. Tighten
    Tighten the nut to 15-18 N·m (11-13 lb ft).

  55. Install the speedometer driven gear assembly (2).

    56. Tighten
    Tighten the bolt to 4-7 N·m (35-62 lb in).

  56. Install the related clutch parts.

    57. Object Number: 1223625 Size: SH
  57. Remove the transaxle assembly from DT 46553  (1).
  58. Install the transaxle assembly. Refer to Transmission Replacement .