GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.
full bulletin at NHTSA ↗2006 Chevrolet Aveo powertrain problems
moderate 12 complaints filed with NHTSA · avg repair $2,500 · see powertrain across all vehicles →
Failure mileage
Complaints
12
Recalls
0
Avg fix
$2,500
When does it fail?
Of the 12 powertrain complaints filed for the 2006 Chevrolet Aveo, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Among the 7 model years of Chevrolet Aveo in our records for powertrain problems, this one ranks #2 by owner-complaint volume.
No new NHTSA powertrain complaint has been filed on this vehicle in over 15 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering powertrain on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This bulletin provides information on the harmful effects of water or ethylene glycol in transmission fluid.
full bulletin at NHTSA ↗This Warranty Admin service bulletin provides guidelines for Dealers Not Required and for Dealers Required to Contact the PQC for engine or transmission assembly replacement and explains the PQC process, GWM Transaction submission, vehicle service record retention and proper handling of assembly returns for Canadian Dealers only.
full bulletin at NHTSA ↗This PI bulletin advises the technician on the proper way to install the pistons in an engine.
full bulletin at NHTSA ↗This service bulletin provides a vibration analysis worksheet the technician can use in conjunction with the appropriate Vibration Analysis-Road testing procedure when diagnosing vibration concerns.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners describe widespread problems with the automatic transmission shifter and ignition lock. The most common complaint is shifter stuck in Park after parking—the key simultaneously locks in the ignition, and the vehicle cannot be restarted without disconnecting the battery. One owner found a peculiar workaround: removing the radio fuse temporarily allows the key and shifter to release, then reinstalling the fuse restores normal function, suggesting an electrical interlock fault.
Failures occur as early as 36,000 miles. Dealerships quote $300–$400 for shift assembly replacement, and one owner reported the problem appeared right after the 36,000-mile mark. Another complaint describes the shifter cable tab fracturing, allowing the vehicle to roll away in Reverse while parked.
Transmission behavior is also erratic. One owner reports the transmission won't shift out of Drive, accompanied by acceleration failure and a rubber smell, recurring repeatedly. Another owner cannot engage Reverse. One vehicle lost power to accelerate on inclines with no diagnosable cause.
A serious structural failure involved an engine motor mount bolt that bent and fractured due to undisclosed frame damage, causing the engine to collapse onto the axle at 45 mph. One owner also reports radiator coolant mixing with transmission fluid, triggering a misdiagnosis and leaving warning lights on after repair.
Throttle body failures and key-in-ignition lock problems round out the powertrain complaints, with repairs not covered under warranty.
Same Chevrolet Aveo powertrain reports on nearby years: 2005 · 2008 · 2009
Failure modes owners describe
Shifter stuck in Park / inability to shift out of Park
Transmission shifter becomes mechanically locked in Park position, preventing gear changes. Multiple owners report key also stuck in ignition simultaneously. One owner notes removing radio fuse temporarily allows shifting; reinstalling fuse restores function, suggesting electrical interlock issue.
When: 36,000–78,000 miles
Symptoms owners cite: Shifter will not move out of Park; Key stuck in ignition locking position; Requires battery disconnect to restart vehicle; Check Engine and Air Bag lights illuminate
Codes mentioned: P0000 (referenced as clock sensor replacement, actual code not stated)
Repairs/costs cited: Dealership quoted $300–$400 for shift assembly replacement. Brake switch and brake transaxle solenoid replacement attempted without success by one owner.
Shifter cable tab fracture
Physical fracture of the shifter cable tab attachment. Vehicle rolled away in reverse after parking when shifter cable failed to hold gear selection.
When: 78,000 miles
Symptoms owners cite: Vehicle rolled away in Reverse after parking; Shifter cable tab visibly fractured
Repairs/costs cited: Shifter cable tab replacement required. Repair not completed per owner report.
Recalls/TSBs owners mention: Manufacturer made aware; no recall or TSB mentioned.
Gear shift locking in position while driving
Shifter becomes mechanically locked or stuck in current gear position during normal operation—while accelerating forward, backing up, or parking.
When: Unknown mileage
Symptoms owners cite: Shifter locks into current position unexpectedly; Occurs while backing up, going forward, or parking
Transmission unable to shift; fails to accelerate
Transmission refuses to shift out of Drive position and vehicle loses power to accelerate. Abnormal rubber smell accompanies failure. Recurs multiple times.
When: 120,000 miles
Symptoms owners cite: Vehicle will not shift out of Drive; Fails to accelerate without warning; Abnormal rubber smell; Failure recurs repeatedly
Repairs/costs cited: Not diagnosed or repaired per owner.
Reverse gear engagement failure
Automatic transmission will not shift into Reverse gear on demand.
When: Early mileage (June 2006)
Symptoms owners cite: Will not shift into Reverse
Repairs/costs cited: Owner planned repair at Tommy Thomas Chevrolet, Panama City, FL.
Engine mount bolt fracture and motor mount failure
Motor mount bolt (hidden under engine, connected to frame) bent and severed 3/4 of the way through due to frame damage and warped undercarriage. Bolt fracture caused engine to collapse onto axle at highway speed, breaking the axle. Frame damage was not disclosed to the buyer.
When: Unknown exact mileage; occurred during 45 mph driving
Symptoms owners cite: Motor mount bolt bent and severely fractured; Engine collapsed and landed on axle while driving 45 mph; Driver-side axle broken; Hidden frame damage and warped undercarriage
Repairs/costs cited: Axle replaced previously. Engine collapse and axle replacement required. Mechanic unable to detect frame damage because it was not disclosed at purchase.
Radiator and transmission fluid cross-contamination
Coolant mixed with transmission fluid, causing transmission hesitation and triggering Check Engine light. Dealership misdiagnosed as faulty clock sensor.
When: 87,794 miles
Symptoms owners cite: Radiator fluid mixed with transmission fluid; Transmission hesitates when shifting gears; Check Engine warning light illuminates
Repairs/costs cited: Clock sensor replaced at Community Chevrolet (Burbank, CA). After repair, Check Engine and Air Bag warning lights remained illuminated.
Throttle body failure
Throttle body required replacement. Failure not covered under warranty.
When: Unknown mileage
Symptoms owners cite: Throttle malfunction
Repairs/costs cited: Throttle body replacement, not covered under warranty.
Key stuck in ignition / ignition lock failure
Key becomes stuck or locked in the ignition, unable to remove from the locking position. Multiple reports describe this occurring independently or paired with shifter lockup. One owner found removing the radio fuse allows key removal.
When: 38,000–87,000 miles
Symptoms owners cite: Key stuck in ignition locking position; Key will not turn or remove; Vehicle cannot be turned off normally (must disconnect battery); Related to radio fuse in at least one case
Repairs/costs cited: Dealership quoted $300 for repair. One owner discovered temporary workaround: remove radio fuse to release key.
Poor acceleration on incline
Vehicle will not accelerate properly when driving uphill. Mechanic unable to diagnose root cause.
When: 38,000 miles
Symptoms owners cite: Inability to properly accelerate on an incline
Repairs/costs cited: Mechanic could not diagnose.
Recalls/TSBs owners mention: Manufacturer made aware.
Synthesized from 12 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Parked the car in a parking spot at a store, went inside for a little while, came back out to have the shifter not shift from park after brake pedal was depressed. I've already tried replacing the brake switch near the brake pedal and replaced the brake transaxle solenoid. Neither option has worked. Took to the dealership to have them look at it. $80 later, they want over 400 to fix the shifter…
Had powertrain trouble with your 2006 Chevrolet Aveo?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the powertrain problem on the 2006 Chevrolet Aveo?
It's a documented issue but not catastrophic. 12 complaints have been filed. Repairs average $2,500 and most owners catch it before it causes a breakdown.
At what mileage does the powertrain typically fail?
Across the 10 complaints that reported odometer mileage, most powertrain failures cluster between 35,983 and 78,000 miles, with the median around 38,857. A quarter of owners report trouble before 35,983; a quarter make it past 78,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $2,500 for powertrain repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to powertrain?
No active recalls currently cover powertrain issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Chevrolet/Aveo.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.