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Home >> Chevrolet >> 2008 >> Optra5 LT, Automatic >> Repair and Diagnosis >> Transmission >> Hydraulic Diagrams >> Automatic Transaxle - AISIN 81-40LE - Service, Overhaul, Removal & Installation & Diagnosis >> Transmission Disassemble >> Disassembly Procedure

Disassembly Procedure

    Fig 1: View Of Transaxle Assembly, Support And DT 46453
    GM1245858Courtesy of GENERAL MOTORS CORP.
  1. Remove the transaxle assembly from the vehicle. Refer to Transmission Replacement .
  2. Install the transaxle assembly to the transaxle support stand using the DT 46469-2  (1). See Special Tools .
    3. Fig 2: View Of PNP Switch, Nut, Washer And Control Lever
    GM1245860Courtesy of GENERAL MOTORS CORP.
  3. Remove the nut, washer and control lever.
  4. Using a screwdriver, unstake the lock washer.
  5. Remove the 2 bolts and nut and pull out the park/neutral position (PNP) switch.
    6. Fig 3: View Of Unions, O-Rings And Transaxle Case
    GM1245859Courtesy of GENERAL MOTORS CORP.
  6. Remove the 2 unions from the transaxle case.
  7. Remove the 2 O-rings from the unions.
    8. Fig 4: View Of Screw Plug, O-Ring And Transaxle Case
    GM1245865Courtesy of GENERAL MOTORS CORP.
  8. Remove the screw plug from the transaxle case.
  9. Remove the O-ring from the screw plug.
    10. Fig 5: Identifying ISS Sensor And Bolts
    GM1245863Courtesy of GENERAL MOTORS CORP.
  10. Remove the bolt and the input shaft speed (ISS) sensor.
  11. Remove the breather plug.
  12. Remove the O-ring from the breather plug.
    13. Fig 6: Identifying OSS Sensor And Bolts
    GM1245864Courtesy of GENERAL MOTORS CORP.
  13. Remove the bolt and the output shaft speed (OSS) sensor.
    14. Fig 7: View Of Oil Pan And Gasket
    GM1245862Courtesy of GENERAL MOTORS CORP.
  14. Remove the 18 bolts.
  15. Remove the oil pan and gasket.
  16. Remove the drain plug from the oil pan.
    17. Fig 8: View Of Oil Strainer And Bolts
    GM1245866Courtesy of GENERAL MOTORS CORP.
  17. Remove the 3 bolts and oil strainer.
    18. Fig 9: View Of Oil Strainer Gasket
    GM1245867Courtesy of GENERAL MOTORS CORP.
  18. Remove the gasket from the oil strainer.
    19. Fig 10: Identifying Solenoid Connectors
    GM1245869Courtesy of GENERAL MOTORS CORP.
  19. Remove the bolt and transmission fluid temperature sensor with the clamp.
  20. Disconnect the 5 solenoid connectors.
    • Lock-up control solenoid (5)
    • Pressure control solenoid (1)
    • No. 2 shift solenoid (2)
    • No. 1 shift solenoid (3)
    • Timing solenoid (4)
    21. Fig 11: Identifying Valve Body Assembly And Bolts
    GM1245868Courtesy of GENERAL MOTORS CORP.
  21. Support the valve body assembly and remove the 14 bolts.
    22. Fig 12: Identifying Manual Valve Control Rod And Manual Valve Lever
    GM1245871Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the manual valve control rod from the manual valve lever, then remove the valve body assembly.
    23. Fig 13: View Of Check Valve And Spring
    GM1245870Courtesy of GENERAL MOTORS CORP.
  23. Remove the check valve and spring.
    24. Fig 14: Identifying Brake Drum Gasket
    GM1245885Courtesy of GENERAL MOTORS CORP.
  24. Remove the brake drum gasket.
    25. Fig 15: Identifying Apply Gasket
    GM1245857Courtesy of GENERAL MOTORS CORP.
  25. Remove the apply gasket.
    26. Fig 16: Applying Compressed Air To Oil Hole
    GM1245875Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.
    IMPORTANT: Take care not to splash automatic transaxle fluid (ATF) when air-blowing.
  26. Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the direct clutch accumulator piston and spring.
  27. Remove the spring.
    28. Fig 17: View Of O-Rings And Direct Clutch Accumulator Piston
    GM1245872Courtesy of GENERAL MOTORS CORP.
  28. Remove the 2 O-rings (1) from the direct clutch accumulator piston.
    29. Fig 18: Applying Compressed Air To Oil Hole
    GM1245874Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.
    IMPORTANT: Take care not to splash automatic transaxle fluid (ATF) when air-blowing.
  29. Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the forward clutch accumulator piston and spring.
  30. Remove the spring.
    31. Fig 19: View Of O-Rings And Forward Clutch Accumulator Piston
    GM1245873Courtesy of GENERAL MOTORS CORP.
  31. Remove the 2 O-rings (1) from the forward clutch accumulator piston.
    32. Fig 20: Applying Compressed Air To Oil Hole
    GM1245879Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.
    IMPORTANT: Take care not to splash automatic transaxle fluid (ATF) when air-blowing.
  32. Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the Over Drive (O/D) and 2nd brake clutch accumulator piston and spring.
    33. Fig 21: View Of O-Rings, O/D And 2nd Brake Accumulator Piston
    GM1245878Courtesy of GENERAL MOTORS CORP.
  33. Remove the 2 O-rings (1) from the O/D and 2nd brake accumulator piston.
    34. Fig 22: View Of Transaxle Wire And Bolt
    GM1245877Courtesy of GENERAL MOTORS CORP.
  34. Remove the bolt and the transaxle wire from the transaxle case.
    35. Fig 23: View Of Transaxle Wire And O-Ring
    GM1245876Courtesy of GENERAL MOTORS CORP.
  35. Remove the O-ring (1) from the transaxle wire.
    36. Fig 24: View Of Transaxle Housing
    GM1245883Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Be careful not to drop the differential gear assembly when the transaxle housing is removed.
  36. Remove the 16 bolts and tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.
    37. Fig 25: Measuring Input Shaft End Play
    GM1245882Courtesy of GENERAL MOTORS CORP.
  37. Using a dial indicator, measure the input shaft end play.

    Specification:  The end play is 0.3-0.9 mm (0.012-0.035 in).

    38. Fig 26: View Of Oil Pump And Bolts
    GM1245881Courtesy of GENERAL MOTORS CORP.
  38. Remove the 6 bolts and oil pump.
    39. Fig 27: View Of Differential Gear Assembly And Transaxle Case
    GM1245884Courtesy of GENERAL MOTORS CORP.
  39. Remove the differential gear assembly from the transaxle case.
    40. Fig 28: View Of Apply Gasket
    GM1245899Courtesy of GENERAL MOTORS CORP.
  40. Remove the apply gasket.
    41. Fig 29: View Of Direct Clutch Assembly And Transaxle Case
    GM1245897Courtesy of GENERAL MOTORS CORP.
  41. Remove the direct clutch assembly from the transaxle case.
    42. Fig 30: View Of Thrust Needle Roller Bearing And Direct Clutch Assembly
    GM1245896Courtesy of GENERAL MOTORS CORP.
  42. Remove the thrust needle roller bearing from the direct clutch assembly.
    43. Fig 31: Identifying Direct Clutch Hub, Thrust Needle Roller Bearing, Race And Transaxle Case
    GM1245895Courtesy of GENERAL MOTORS CORP.
  43. Remove the direct clutch hub, thrust needle roller bearing and thrust bearing race from the transaxle case.
    44. Fig 32: View Of Counter Driven Gear Assembly And Transaxle Case
    GM1245890Courtesy of GENERAL MOTORS CORP.
  44. Remove the counter driven gear assembly from the transaxle case.
    45. Fig 33: View Of Transaxle Rear Cover And Bolts
    GM1245894Courtesy of GENERAL MOTORS CORP.
  45. Remove the 9 bolts and tap on the circumference of the transaxle rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.
    46. Fig 34: Identifying Apply Gaskets
    GM1245893Courtesy of GENERAL MOTORS CORP.
  46. Remove the 4 apply gaskets.
    47. Fig 35: Identifying O/D Brake Flange, Discs And Plates
    GM1245889Courtesy of GENERAL MOTORS CORP.
  47. Remove 2nd coast and O/D brake flange (1), 2 discs (2), and 2 plates (3) from the transaxle case.
    48. Fig 36: View Of Thrust Needle Roller Bearing And Forward/Reverse Clutch Assembly
    GM1245892Courtesy of GENERAL MOTORS CORP.
  48. Remove the thrust needle roller bearing and forward and reverse clutch assembly.
    49. Fig 37: Identifying Thrust Needle Roller Bearing, Race And Forward/Reverse Clutch Assembly
    GM1245888Courtesy of GENERAL MOTORS CORP.
  49. Remove the thrust needle roller bearing and thrust bearing race from the forward and reverse clutch assembly.
    50. Fig 38: View Of Forward Clutch Hub And Transaxle Case
    GM1245886Courtesy of GENERAL MOTORS CORP.
  50. Remove the forward clutch hub from the transaxle case.
    51. Fig 39: Identifying Thrust Needle Roller Bearing And Forward Clutch Hub
    GM1245905Courtesy of GENERAL MOTORS CORP.
  51. Remove the thrust bearing race and thrust needle roller bearing from the forward clutch hub.
    52. Fig 40: View Of Rear Planetary Sun Gear And 1-Way Clutch Assembly
    GM1245900Courtesy of GENERAL MOTORS CORP.
  52. Remove rear planetary sun gear and 1-way clutch assembly.
    53. Fig 41: Identifying Thrust Needle Bearing Race, Rear Planetary Sun Gear And 1-Way Clutch Assembly
    GM1245903Courtesy of GENERAL MOTORS CORP.
  53. Remove the thrust bearing race from the rear planetary sun gear and 1-way clutch assembly.
    54. Fig 42: View Of Thrust Needle Bearing Race, Planetary Carrier Thrust Washer, Rear Planetary Sun Gear And 1-Way Clutch Assembly
    GM1245902Courtesy of GENERAL MOTORS CORP.
  54. Remove the thrust needle roller bearing and planetary carrier thrust washer from the rear planetary sun gear and 1-way clutch assembly.
    55. Fig 43: View Of 1-Way Clutch Assembly, Thrust Washer And Rear Planetary Sun Gear
    GM1245904Courtesy of GENERAL MOTORS CORP.
  55. Remove the 1-way clutch assembly and thrust washer from the rear planetary sun gear.
    56. Fig 44: Identifying Front Planetary Sun Gear And Thrust Bearing Race
    GM1245907Courtesy of GENERAL MOTORS CORP.
  56. Remove the front planetary sun gear from the transaxle case.
  57. Remove the thrust bearing race from the front planetary sun gear.
    58. Fig 45: Identifying DT 46455 And DT 46458
    GM1245908Courtesy of GENERAL MOTORS CORP.
  58. Using the DT 46455  (1) and DT 46458  (2), remove the 2 snap rings, 2nd brake piston, and 2nd brake piston return spring. See Special Tools .
    59. Fig 46: Applying Compressed Air To 2nd Brake
    GM1245909Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.
    IMPORTANT: Take care not to splash automatic transaxle fluid (ATF) when air-blowing.
  59. Apply 392 kPa (57 psi)  of compressed air to the 2nd brake to remove the 2nd brake piston from the 2nd brake clutch cylinder.
    60. Fig 47: Identifying 2nd Brake Piston O-Rings
    GM1245910Courtesy of GENERAL MOTORS CORP.
  60. Remove the 2 O-rings (1) from the 2nd brake piston.
    61. Fig 48: View Of Plates, Discs And Flange
    GM1245911Courtesy of GENERAL MOTORS CORP.
  61. Remove the 2 plates, 2 discs, and flange.
    62. Fig 49: View Of No. 2 One Way Clutch And Planetary Gear
    GM1245912Courtesy of GENERAL MOTORS CORP.
  62. Remove the No. 2 1-way clutch and planetary gear from the transaxle case.
    63. Fig 50: No. 2 1-Way Clutch, Planetary Gear And Anti-Rattle Clip
    GM1245913Courtesy of GENERAL MOTORS CORP.
  63. Remove the No. 2 1-way clutch from the planetary gear and remove the anti-rattle clip.
    64. Fig 51: View Of Counter Drive Gear And Parking Lock Pawl
    GM1245914Courtesy of GENERAL MOTORS CORP.
  64. Fix the counter drive gear with the parking lock pawl.
    65. Fig 52: Removing Planetary Ring Gear Nut Using DT 46472
    GM1245906Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not chisel and remove the planetary ring gear nut staking before removing the nut. Damage to the planetary ring gear could result if force is applied. Remove the nut without unstaking the planetary ring gear. If force is used to unstake the planetary ring gear nut, damage the bearing could result.
  65. Remove the planetary ring gear nut using planetary ring gear nut removal/installation socket DT 46472  (1). See Special Tools .
    66. Fig 53: View Of Parking Lock Pawl Bracket And Bolts
    GM1245915Courtesy of GENERAL MOTORS CORP.
  66. Remove the 2 bolts and parking lock pawl bracket.
    67. Fig 54: View Of Parking Lock Pawl, Shaft And Torsion Spring
    GM1245916Courtesy of GENERAL MOTORS CORP.
  67. Remove the parking lock pawl shaft, torsion spring and parking lock pawl.
    68. Fig 55: View Of Bolt And Manual Detent Spring
    GM1245917Courtesy of GENERAL MOTORS CORP.
  68. Remove the bolt and manual detent spring.
    69. Fig 56: Removing Spacer Using A Chisel And Hammer
    GM1245918Courtesy of GENERAL MOTORS CORP.
  69. Using a chisel and hammer, unstake and remove the spacer.
    70. Fig 57: Driving The Pin Using A Pin Punch And Hammer
    GM1245919Courtesy of GENERAL MOTORS CORP.
  70. Using a pin punch and hammer, drive out the pin.
    71. Fig 58: View Of Manual Valve Lever And Shaft
    GM1245920Courtesy of GENERAL MOTORS CORP.
  71. Remove the manual valve lever shaft and manual valve lever.
    72. Fig 59: View Of Parking Lock Rod And Manual Valve Lever
    GM1245921Courtesy of GENERAL MOTORS CORP.
  72. Remove the parking lock rod from the manual valve lever.
    73. Fig 60: Removing Oil Seal Using A Screwdriver
    GM1245927Courtesy of GENERAL MOTORS CORP.
  73. Using a screwdriver, remove the oil seal.
    74. Fig 61: Identifying Planetary Ring Gear, DT 46455, DT 46457 And DT 46459
    GM1245922Courtesy of GENERAL MOTORS CORP.
  74. Using the DT 46455  (2), DT 46457  (3), and DT 46459  (1), remove the planetary ring gear. See Special Tools .
    75. Fig 62: View Of Counter Drive Gear And Bolts
    GM1245932Courtesy of GENERAL MOTORS CORP.
  75. Install the 3 bolts to the counter drive gear.

    Specification: 

    • The bolt (M6) L is equal to 40-80 mm (1.57-3.15 in).
    • The bolt (M6) pitch is equal to 1.0 mm (0.04 in).

  76. Rotate 3 bolts in order and remove the counter drive gear and planetary ring gear.
    77. Fig 63: Identifying DT 46455, DT 46457, 1st And Reverse Brake Snap Ring
    GM1245938Courtesy of GENERAL MOTORS CORP.
    CAUTION: Use extreme care when removing snap rings. Always wear adequate eye protection in order to avoid personal injury.
  77. Using the DT 46455  (1) and DT 46457  (2), remove the snap ring of 1st and reverse brake. See Special Tools .
    78. Fig 64: View Of Flange, Discs, Plates And Return Spring
    GM1245929Courtesy of GENERAL MOTORS CORP.
  78. Remove the flange, 4 discs, 4 plates, and return spring.
    79. Fig 65: Applying Compressed Air To Transaxle Case
    GM1245923Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.
    IMPORTANT: Take care not to splash automatic transaxle fluid (ATF) when air-blowing.
  79. Apply 392 kPa (57 psi)  of compressed air to the transaxle case (1) to remove the 1st and reverse brake piston.
    80. Fig 66: Identifying 1st And Reverse Brake Piston O-Rings
    GM1245934Courtesy of GENERAL MOTORS CORP.
  80. Remove the 2 O-rings (1) from the 1st and reverse brake piston.
    81. Fig 67: View Of No. 1 Transaxle Case Plate And Bolt
    GM1245939Courtesy of GENERAL MOTORS CORP.
  81. Remove the bolt and No. 1 transaxle case plate from the transaxle case.
    82. Fig 68: Identifying Counter Driven Gear Outer Tapered Roller Bearing Race And Shim
    GM1245930Courtesy of GENERAL MOTORS CORP.
  82. Using a suitable puller, remove the counter driven gear outer tapered roller bearing race and shim from the transaxle case.
  83. Using a driver, remove the oil seal from the transaxle case.
    84. Fig 69: View Of Transaxle Case Side Bearing Outer Race And Shim Removal Tools
    GM1245925Courtesy of GENERAL MOTORS CORP.
  84. Using the DT 46463  (2) and DT 46465  (1), remove the transaxle case side bearing outer race and shim. See Special Tools .
    85. Fig 70: View Of Oil Reservoir Lock Plate And Bolts
    GM1245935Courtesy of GENERAL MOTORS CORP.
  85. Remove the 3 bolts and oil reservoir lock plate from the transaxle housing.
    86. Fig 71: View Of No. 1 Transaxle Apply Pipe Clamp
    GM1245940Courtesy of GENERAL MOTORS CORP.
  86. Remove the bolt and No. 1 transaxle apply pipe clamp from the transaxle housing.
  87. Remove the transaxle lube apply pipe and differential gear lube apply pipe from the transaxle housing.
    88. Fig 72: Identifying Oil Seal And Transaxle Housing
    GM1245931Courtesy of GENERAL MOTORS CORP.
  88. Using a suitable puller, remove the counter driven gear outer tapered roller bearing race from the transaxle housing.
  89. Using a driver, remove the oil seal from the transaxle housing.
    90. Fig 73: Removing Side Bearing Outer Race And Transaxle Housing Using A Puller
    GM1245926Courtesy of GENERAL MOTORS CORP.
  90. Using a suitable puller, remove the side bearing outer race from the transaxle housing.
    91. Fig 74: View Of Driver, DT 46451 And DT46454
    GM1245936Courtesy of GENERAL MOTORS CORP.
    CAUTION: Use extreme care when removing snap rings. Always wear adequate eye protection in order to avoid personal injury.
  91. Using the DT 46451  (1), DT 46454  (2) and a driver, remove the snap ring. See Special Tools .
    92. Fig 75: View Of O/D Brake Return Spring
    GM1245941Courtesy of GENERAL MOTORS CORP.
  92. Remove the O/D brake return spring.
    93. Fig 76: Applying Compressed Air To Transaxle Rear Cover
    GM1245943Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.
    IMPORTANT: Take care not to splash automatic transaxle fluid (ATF) when air-blowing.
  93. Apply 392 kPa (57 psi)  of compressed air to the transaxle rear cover to remove the O/D brake piston.
    94. Fig 77: View Of O/D Brake Piston And O-Rings
    GM1245947Courtesy of GENERAL MOTORS CORP.
  94. Remove the 2 O-rings (1) from the O/D brake piston.
    95. Fig 78: View Of Transaxle Rear Cover And Seal Rings
    GM1245946Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not expand the seal ring excessively.
  95. Remove the 2 seal rings from the transaxle rear cover.
    96. Fig 79: View Of Transaxle Rear Cover, Screw Plugs And 4 O-Rings
    GM1245944Courtesy of GENERAL MOTORS CORP.
  96. Remove the 4 screw plugs and 4 O-rings from the transaxle rear cover.
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