Chevrolet Aveo T200 factory workshop and repair manual

Tools & consumables
- Basic hand tools: metric sockets (8–24 mm), ratchet, extensions, breaker bar, combination wrenches.
- Torque wrench (0–200 Nm range).
- Impact or 1¼" (approx) axle nut socket (size depends on model; check exact).
- Ball joint separator / pickle fork, tie-rod puller.
- Pry bars, hammer, punch.
- Snap-ring pliers (internal/external as required).
- Puller / press (hydraulic press or shop-type slide hammer/puller) to extract coupling or flange.
- Seal puller, picks, gasket scraper.
- Drain pan, rags, brake cleaner.
- Transmission/differential fluid pump and refill hose.
- Jack, jack stands, wheel chocks.
- Service manual (OEM spec sheet).
Consumables/parts
- Replacement viscous coupling unit (OEM part number for Aveo T200 AWD/LS differential) — do not reuse.
- New axle nut(s), differential/engine/transaxle oil (type & qty per manual), new seals/Gaskets and O-rings, replacement bolts if recommended.
- Threadlock (blue) if specified by manual.
Safety
- Work on level ground; chock rear wheels and set parking brake.
- Use quality jack stands — never rely on a jack alone.
- Wear eye protection and gloves; drain fluids into proper container and dispose properly.
- Support suspension components — do not let them hang on brake lines.
Step-by-step procedure (typical viscous coupling replacement on a T200 transaxle differential)
Note: Confirm the vehicle actually uses a viscous coupling assembly (some Aveo T200 base FWD do not). The procedure below covers removing the halfshaft/hub to access the transaxle output flange and removing the coupling from the transaxle/differential carrier — adapt per service manual.

1) Preparation
- Park, chock, lift front of vehicle and support on stands. Remove front wheels.
- Remove any undertray or splash shields to access transaxle/differential area.

2) Remove halfshaft from hub
- Break loose and remove the axle nut (use appropriate axle nut socket; may be staked — un-stake first).
- Remove brake caliper and hang it safely (do not let it hang by hose).
- Remove brake disc if needed for clearance.
- Separate lower ball joint or tie-rod (as required) using ball joint separator to allow steering knuckle to swing out. Support the knuckle; do not overstress the CV boot.
- Pull halfshaft out of the hub assembly; you may need a slide-hammer or firm pry after removing retaining circlip at transaxle end. Keep track of any snap rings.

3) Drain transaxle/differential fluid
- Place drain pan under transaxle. Remove drain/filler plug(s) and drain fluid fully. Save or dispose per law.

4) Remove transaxle/differential cover or carrier access
- Depending on design, remove differential case cover or unbolt the differential carrier to access the viscous coupling assembly. On many Aveo transaxles the output flange/coupling is inside the case — consult manual for exact access points.
- Remove any linkage, sensors or bracket interfering with access.

5) Access the viscous coupling
- Remove retaining bolts/fasteners that hold the coupling/flange assembly to the output shaft. There may be a circlip or large nut holding the coupling in place.
- Use snap-ring pliers to remove circlip. Use a puller or press to extract the coupling assembly from the output shaft flange. If the coupling is splined on the shaft, a slide hammer with an appropriate adapter or a hydraulic press will remove it. Use even pressure — do not distort the housing or mating faces.

Tool usage details:
- Snap-ring pliers: Use the correct internal/external type. Compress the ring while maintaining steady pressure; remove slowly to avoid ring launching.
- Puller/press: Attach puller arms to coupling flange or hub flats. Tighten center forcing screw evenly. If using a hydraulic press, support the assembly on parallel plates and press the coupling straight off the shaft. Protect mating surfaces with soft aluminum blocks to avoid damage.
- Slide hammer: Fit adapter to coupling hub (not to fragile fins); strike firmly and evenly until it pulls free.

6) Inspect and prepare replacement
- Inspect mating splines, shaft for wear, chips or scoring. Replace shaft or transaxle parts if damaged.
- Replace axle seals and O-rings at output shaft and hub as required.
- Compare old viscous coupling with new to ensure matching spline count and flanges.

7) Install new viscous coupling
- Clean splines and lightly coat with specified grease or assembly lube per manual (if specified — sometimes dry install is required; check OEM).
- Press new coupling onto shaft straight — use press or carefully tap on using a soft-faced mallet while supporting the coupling face. Ensure the circlip groove aligns.
- Install circlip or retaining nut and torque to OEM spec. If the assembly uses torque-to-yield bolts or threadlocker, follow manual instructions.
- Reassemble differential carrier or cover with new gasket/sealant and torque bolts to spec.

8) Reinstall halfshaft and suspension components
- Reinsert halfshaft into transaxle until snapped in (listen/feel for snap on circlip), guide other end into hub assembly.
- Reinstall hub nut finger tight then torque to specified value while vehicle is on ground later (or follow manual: some require stub axle nut torqued to spec with vehicle weight).
- Reinstall brake disc, caliper, and any removed suspension components. Re-stake axle nut if originally staked (replace with new nut if required).

9) Refill fluid and final checks
- Refill transaxle with correct type and quantity of fluid per manual.
- Cycle steering and rotate wheels to seat parts. Lower vehicle to ground, torque axle nut to final spec if required with weight on wheels.
- Road test carefully. Check for leaks, noises, proper engagement.

Common pitfalls & cautions
- Confirm vehicle actually uses a viscous coupling — do not tear into transaxle unnecessarily.
- Do not reuse the viscous coupling — internal silicone/platel assembly is non-serviceable.
- Don’t overheat or contaminate the new coupling with solvents or debris.
- Always replace seals and gaskets when opening the unit; reused seals are a common leak source.
- Avoid prying on the transaxle case or forcing parts crooked — splines and bearing seats are easily damaged.
- Use proper puller/press tooling — hammering the coupling axially without support can distort hub and cause vibration.
- Torque to OEM specs — under/over-torquing causes bearing failure or slippage.
- If you find excessive backlash, metal shavings, or damaged spider gears — stop and rebuild the differential properly or replace the carrier.
- Dispose of old fluid and viscous coupler per environmental regulations.

Replacement parts required (typical)
- Viscous coupling assembly (OEM)
- Output shaft/axle seal(s)
- Differential/transaxle fluid (OEM spec)
- Gasket or RTV sealant for cover
- New axle nut(s) (recommended)
- Any damaged bolts, circlips or retaining hardware

Final notes
- Exact disassembly order, splines, circlip locations and torque specs vary by transaxle variant — follow the Aveo T200 service manual for exact values and drawings.
- If you don’t have a hydraulic press or appropriate puller, don’t improvise — take the assembly to a shop to avoid damage.
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