Assembly of the main transmission units (Chevrolet Aveo T200)

Assembly

1. Connect the driven and driving shafts.

2. Compress the snap ring at the base of the driven shaft and hold it with the holder.

3. Hold the retaining ring at the base of the input shaft with round-nose pliers.

4. Install the main and input shafts onto the support plate.

5. Loosen the main shaft retaining ring and the input shaft retaining ring.



6. Install the 1st and 2nd gear forks.

7. Install the 5th gear lever into the support plate.



8. Install the 3-4th gear shift rod/fork retaining pin.



9. Install the thrust bracket onto the bearing housing.





10. Install the 1st and 2nd gear rod/fork onto the bearing housing.



11. Install the 1-2 gear fork retaining pin.



12. Install the thrust bracket and tighten the mounting screws to 7 Nm.



13. Install the reverse gear rod/fork into the bearing housing.





14. Install the reverse gear rod/fork retaining pin.



15. Install the rod locking pin and spring into the locking hole.



16. Install the 4th gear rod locks.



17. Tighten the bolts and install the 5th gear connector to the bearing housing using the snap fastener.

Tightening

Tighten the connector bolts to 7 Nm.



18. Install the 5th gear pinion.



19. Secure the 5th gear with a retaining ring.



20. Install the thrust washers, retaining ring and needle bearing into the 5th gear main shaft assembly.



21. Install the synchronizer locking ring on the 5th gear driven gear of the main shaft.





22. Install the driven shaft 5th gear driven gear assembly.



23. Install the 5th gear clutch hub.

24. Install the snap ring holding the 5th gear assembly.



25. Install the 5th gear fork and tighten the 5th gear fork mounting screws to a torque of 22 Nm.



26. Engage 2nd gear.



27. Install the bearing housing with the shafts attached to it and tighten the mounting screws to a torque of 22 Nm.





29. Install the speedometer drive and tighten the mounting screw to 4 Nm.



30. Install the shift rod, shift lever and pin.



31. Install the retaining ring, bushing, spring and intermediate lever.

33. Shift into neutral.



34. Install the shift lever cover and tighten the mounting screws to 22 Nm.



35. Install the gearbox cover and tighten the mounting screws to 18 Nm.

36. Install the gearbox on the vehicle.

(The original article can be found on the resource ChevyMan.ru)