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Chevrolet Aveo T200 factory workshop and repair manual

Why this repair is needed — plain language
- The transmission pan and its gasket form a leak-proof joint at the bottom of an automatic transmission. The pan holds the transmission fluid (ATF) at the lowest point and gives access to the filter and a magnet that collects metal debris.
- Over time the gasket compresses, hardens, tears, or the pan bolts back off a little. That lets ATF leak out. Low ATF causes slipping, hard shifts, overheating and rapid internal wear — like running your engine without oil.
- Think of the gasket like the rubber seal on a jam jar lid. If the seal is old or dirty the jam seeps out. The pan gasket seals the transmission fluid in; replace it when it leaks.

How the system works (brief, practical)
- ATF is the hydraulic fluid and lubricant for the automatic transmission. The transmission pump (driven by the torque converter) draws ATF from the pan, sends it through the filter and valve body, and routes it to clutches, bands and cooling lines. The pan is simply the reservoir and service access.
- The filter captures metal particles and debris; the magnet(s) at the pan/inside the pan attract ferrous particles. If the filter gets clogged or ATF is too low/dirty, hydraulic pressure and control are compromised.
- Replacing the gasket/pan seal is a basic maintenance/repair to stop external leaks and keep internal fluid at the correct level.

What can go wrong if not done correctly
- Over-tightening bolts: warps pan, strips threads, or squeezes gasket wrong — causes leaks.
- Under-tightening bolts: leaks.
- Using wrong gasket or gasket sealer in the wrong place: improper seal.
- Cross-threading bolts: damages case, expensive repair.
- Not replacing/inspecting filter or magnet: lets debris stay in system and cause damage.
- Using wrong ATF or incorrect level: poor shift quality, internal damage.
- Not safely supporting the car: risk of crush injuries.

Parts & components (every component you’ll encounter)
- Transmission pan: stamped steel or aluminum tray that bolts to transmission case.
- Pan gasket: paper, cork, rubber or molded nitrile gasket that fits between pan and transmission case.
- Pan bolts: typically many small bolts (often M6) around pan perimeter; some may be longer; keep track.
- Drain plug: some pans have one; others don’t. If present, used to drain fluid without removing pan.
- ATF (automatic transmission fluid): type specified by manufacturer (see below).
- Transmission filter (serviceable): plastic/screen element that connects to valve body; traps debris.
- Magnet(s): small permanent magnets attached to the pan or inside it to collect metal flakes.
- Valve body (not removed for gasket replacement unless servicing deeper): distribution/valving for hydraulic circuits.
- Transmission case mating surface: the machined surface on the transmission housing where gasket seals.
- Cooler lines/fittings: metal hoses that carry ATF to the radiator cooler; usually above the pan.
- Dipstick & fill tube (if equipped): used to add and check ATF level.

Tools & supplies you need
- Safety: eye protection, nitrile gloves, shop rags.
- Jack and jack stands or ramps (do NOT rely on jack only). Wheel chocks.
- Drain pan (large capacity; ATF is slippery).
- Socket set (likely 8 mm or 10 mm for pan bolts), ratchet, extensions.
- Torque wrench (capable of small torques, e.g., 5–25 ft·lb range).
- Flat gasket scraper or plastic putty knife (non-marring).
- Brake cleaner or ATF-safe solvent, clean shop towels.
- New pan gasket (exact fit for Aveo T200) OR approved gasket maker if required by manual.
- New transmission filter (if removable).
- New pan bolts if any are damaged or if specified as torque-to-yield (rare).
- Replacement ATF — correct spec (see below), funnel and measuring container.
- Small brush and magnet-safe cleaner to clean the pan and magnet.
- Container to temporarily hold removed bolts in order and small labels if needed.

Fluid type and capacities (confirm in your manual; these are typical)
- Typical for many Aveo T200 automatics: Dexron II/III/VI compatible ATF. Dexron VI is backward-compatible but check vehicle placard/owner’s manual for the exact spec. When in doubt, confirm with the service manual or local dealer.
- Fluid lost when you drop the pan: usually 2.0–3.0 L (about 2–3 quarts). Full trans capacity: ~5–7 L (depends on transmission). When servicing pan/filter you only replace part of the system’s fluid; plan to add 2–4 L.

Safety first (non-negotiable)
- Park on level ground, set parking brake, chock wheels.
- Support car with jack stands securely; never work under a vehicle supported only by a hydraulic jack.
- Transmission fluid is hot if recently driven; allow to cool or use gloves/eye protection.
- ATF is waste oil — dispose/recycle properly at an auto parts store or recycling center.

Step-by-step procedure (beginner-friendly)
1) Prepare
- Gather tools, parts, drain pan and new gasket and filter.
- Verify ATF type and measure/mark how much fluid you’ll add back (have 3–4 L ready).
- Warm engine briefly (5–10 minutes) to warm ATF (warmer fluid drains easier), but don’t work on very hot fluid. Turn off engine.

2) Raise and secure vehicle
- Chock rear wheels, jack up front, set on stands. Make sure vehicle is stable and level.

3) Locate pan and drain
- Find transmission pan under the engine bay. Identify drain plug if present.
- Position the drain pan under the pan. If the pan has a drain plug, remove it first to drain most fluid. If no drain plug, loosen pan bolts—leave most bolts threaded in a few turns to hold the pan until you get to one side to control drain.

4) Loosen pan bolts in stages
- Loosen all pan bolts a few turns except one long side bolt. Then support the pan with a hand and slowly loosen the last bolts on one side. Lower the side away from the bolts so fluid drains into catch.
- Tip: leave one corner bolt partially threaded as a hinge as you break the seal, then remove it and lower the pan fully once draining slows.

5) Remove pan and inspect contents
- Carefully lower and remove pan. Expect several liters of fluid to pour out — keep drain pan under control.
- Inspect pan interior and magnet(s). The magnet will be dirty: wipe it clean. Small fine metallic dust is normal; large chunks or heavy scoring indicates abnormal wear.
- Inspect pan gasket surface for metal flakes, heavy contamination, chunks, or linear scoring/ridges — these suggest internal wear.

6) Remove and inspect filter
- Remove the transmission filter (usually held by bolts or snaps). Inspect for heavy metal debris or clutch material; small metal shavings are common.
- Replace filter with new one. If filter mounting hardware uses small O-rings, replace those if provided.

7) Clean pan and magnet
- Clean the pan with solvent and rag. Remove old gasket material from both pan and transmission mating surface using plastic scraper. Don’t gouge the machined surface.
- Clean magnet(s) and reinstall them in the pan in the same orientation.

8) Clean mating surface thoroughly
- Use a clean lint-free rag and solvent to remove oil and debris from the transmission case mating surface. No old gasket residue should remain. Avoid dropping anything into the open transmission.

9) Install new gasket (or sealant)
- If using a preformed gasket, position it on the pan mating surface. Many paper/molded gaskets are dry-fit — do not use RTV unless specified by the gasket/manufacturer or manual.
- If a small bead of RTV is required for spots (for some designs), apply a thin, continuous bead per the manual and allow proper flash time.
- If pan bolts are of different lengths, make sure each bolt returns to its original hole (keep track during removal).

10) Reinstall filter
- Install new filter and torque the retaining bolts to specified value if applicable (hand-tight then a small final torque — often low). Consult the new filter instructions or manual.

11) Reattach the pan
- Lift pan into place with the new gasket aligned. Start all bolts by hand to avoid cross-threading.
- Tighten bolts finger-tight in a criss-cross/star pattern to seat gasket evenly. Then torque them in several passes to the specified torque.

Typical torque guidance (general): 8–10 Nm (71–89 in·lb) for small pan bolts; do not exceed 10–12 Nm unless manual specifies. Tighten in a criss-cross pattern working from the center outward in small increments. Consult the service manual for exact torque.

12) Refill ATF
- Lower vehicle to the ground. Add ATF via dipstick/fill tube using a funnel. Start by adding the approximate amount you lost (about 2–3 L), then top up as required to reach the correct level during the check procedure below.
- If vehicle has a service/fill plug on the transmission body (some do), the fill procedure differs — check the manual.

13) Start engine and warm up
- Start engine, leave it in Park (with parking brake on). Let it idle and go through the gear selector slowly to circulate fluid (P-R-N-D-2-1 and back). Keep engine idling and check for external leaks around the pan.
- With engine warm and idling, check the ATF level per the owner’s manual: many GM autos require checking with engine running and at operating temperature. Add fluid slowly — small amounts at a time — do not overfill.

14) Final checks
- Road test gently, then re-check fluid level and inspect for leaks after a short drive and again after a day of driving. Re-torque bolts after initial warm-up only if manual recommends; otherwise check visually for leaks.

Useful tips and traps
- Keep bolts organized; some pans have bolts of different lengths or washers. Put bolts back where they came from.
- Don’t scrape aggressively; you can mar the transmission case surface and cause leaks.
- If you see lots of copper/orange clutch plate material or large metal chunks on the magnet/filter, that suggests internal failure — stop and consult a transmission specialist.
- If you can’t get a good seal with a new gasket or pan is dented/warped, replace the pan.
- Don’t mix ATF types. Use the spec recommended in the owner’s manual. Wrong fluid can change friction characteristics and cause slipping or harsh shifts.

Post-repair monitoring
- Check fluid level and leaks after 50–100 miles and periodically over the next week.
- Monitor shift quality for soft/harsh shifts; abnormal behavior may indicate low fluid, wrong fluid, or internal problems.
- Keep the used ATF and contaminated parts for proper recycling.

Disposal
- Store used ATF in a sealed container and take it to a recycling center or auto parts store that accepts used oil/ATF. Do not pour down drains or on ground.

Quick troubleshooting guide
- Small drips after repair: tighten bolts in cross pattern to spec; re-clean mating surface if persistent.
- Persistent leak at one corner: bolt may be cross-threaded or pan warped — remove, inspect threads and pan.
- Large metal chunks on magnet or filter: internal damage — do not drive the car; consult a specialist.

Time estimate
- 60–120 minutes for a beginner (includes cleanup and care). If you replace the filter and take extra care, budget two hours.

Final note (no Yapping)
- Confirm exact ATF spec and torque values for your model year Aveo T200 in the factory service manual. If you encounter heavy metal debris, or the mating surface or bolts are damaged, stop and get professional help — internal transmission repairs are complicated and expensive.
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