GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Aveo 🢒 Transmission 🢒 Manual Transmission - Y4M 🢒 Transmission Disassemble

Tools Required

    • DT 46496 (DW09940-53111) Gear, Bearing Installer
    • DT 46553 (DW220-010A) Transaxle Fixture
    • DT 47515 (DW220-100) Needle Bearing Remover

    Object Number: 1223625 Size: SH
  1. Remove the manual transaxle. Refer to Transmission Replacement.
  2. Position the manual transaxle to a transaxle stand using DT 46553  (1).

    3. Object Number: 1223672 Size: SH
  3. Remove the related clutch parts.
  4. Remove the manual transaxle mounting bracket bolts (1).
  5. Remove the manual transaxle mounting bracket nut (3).
  6. Remove the manual transaxle mounting bracket (2).

    7. Object Number: 1223673 Size: SH
  7. Remove the backup light switch nut (1).
  8. Disconnect the backup light switch (4).
  9. Remove the speedometer driven gear assembly bolt (3).
  10. Remove the speedometer driven gear assembly (2).

    11. Object Number: 1240927 Size: SH

    Important: Remove the shift interlock bolt. Otherwise, the gear shift and shaft assembly can not be removed.

  11. Remove the shift interlock bolt.

    12. Object Number: 1223694 Size: SH
  12. Remove the side cover bolts (1).
  13. Remove the side cover using a rubber hammer (2).
  14. Remove the sealant on the side cover and the transaxle case.

    15. Object Number: 1223679 Size: SH
  15. Remove the 5th gear shift fork plug (1).
  16. Remove the 5th gear shift fork guide ball using a magnet.
  17. Remove the 5th gear shift fork snap ring (2).
  18. Remove the 5th gear synchronizer plate.

    19. Object Number: 1223700 Size: SH
  19. Shift the shift fork to the 5th gear.
  20. Remove the fork pin using a pin punch and a hammer (1).
  21. Remove the 5th gear shift fork pin.

    22. Object Number: 1223689 Size: SH
  22. Pull and remove the input shaft 5th gear fork and the synchronizer hub assembly together (1).
  23. Remove the sleeve, key and spring from the synchronizer hub assembly.

    24. Object Number: 1223684 Size: SH
  24. Pull and remove the input shaft 5th gear, wave spring and synchronizer ring together (1).
  25. Remove the 5th gear bearing.

    26. Object Number: 1223677 Size: SH
  26. Shift yoke using a driver to engage the 1st gear and the 3rd gear or the 2nd gear and the 4th gear (2).
  27. Remove the stake and the nut (1).

    28. Object Number: 1223699 Size: SH
  28. Remove the countershaft 5th gear (1).

    29. Object Number: 1223687 Size: SH
  29. Remove the side cover plate bolts (1).
  30. Remove the side cover plate (2).
  31. Remove the counter shaft bearing shim.

    32. Object Number: 1223682 Size: SH

    Important: There is a difference between the 5th reverse gear shift shaft spring and the others. Mark it to distinguish easily when installing.

  32. Remove the bolt and remove the 5th reverse gear shift shaft spring and ball (3).
  33. Remove the bolt and remove the 3rd-4th gear shift shaft spring and ball (1).
  34. Remove the bolt and remove the 1st and 2nd gear shift shaft spring and ball (2).

    35. Object Number: 1223676 Size: SH
  35. Remove the reverse idle gear shaft bolt.

    36. Object Number: 1223697 Size: SH
  36. Remove the bolts from the left side case (1).
  37. Remove the bolts from the right side of case (2).
  38. Remove the left side case by hitting with a rubber hammer lightly.
  39. Remove the sealant on the case.
  40. Remove the transaxle case - left.

    41. Object Number: 1223686 Size: SH
  41. Remove the bolts (1).
  42. Remove the reverse gear shift lever (2).

    43. Object Number: 1223680 Size: SH
  43. Push the reverse idle gear toward the inner case.
  44. Pulling shaft and remove the reverse idle gear and shaft (1).
  45. Remove the reverse idle gear from the shaft assembly.

    46. Object Number: 1223674 Size: SH
  46. Remove the 5th reverse gear shift shaft (1).

    47. Object Number: 1240970 Size: SH
  47. Remove the shift and select lever inner and outer pins.

    48. Object Number: 1240975 Size: SH
  48. Remove the gear shift and select shaft assembly.
  49. Remove the shift and select shaft (4).
  50. Remove the gear select spring assemblies (2).
  51. Remove the gear shift interlock plate (9).
  52. Remove the gear shift lever (8).
  53. Remove the 5th and reverse gear shift cam (3).
  54. Remove the return spring (7).
  55. Remove the shift and select bellows (5).
  56. Remove the shift and select shaft oil seal (6).

    57. Object Number: 1240976 Size: SH
  57. Remove the shift and select shaft needle bearings using the DT 47515  (1).

    58. Object Number: 1223738 Size: SH

    Important: Be careful not to damage the teeth of the counter shaft pinion and the differential ring gear.

  58. Remove the gear unit and the shift shaft assembly together (1).
  59. Remove the high and the low speed shift shaft assembly from the gear unit.

    60. Object Number: 1223693 Size: SH
  60. Insert a wooden prying device into the lower side of the differential (2).
  61. Remove the differential assembly by moving it right and left (1).

    62. Object Number: 1223719 Size: SH
  62. Remove the bolt (1).
  63. Remove the oil gutter (2).
  64. Remove the bolts (5).
  65. Remove the oil plate (3).
  66. Remove the differential left side oil seal using a hammer and a copper chisel (4).
  67. Remove the related parts of the transaxle case, left side.

    68. Object Number: 1223709 Size: SH
  68. Remove the oil level plug, including the steel gasket (2).
  69. Remove the counter shaft bearing outer race using a hammer and DT 46496  (1).

    70. Object Number: 1223737 Size: SH
  70. Remove the related parts of the transaxle case - right side.
  71. Remove the input shaft oil seal using a screwdriver (2).
  72. Remove the differential left side oil seal using a hammer and a copper chisel (1).