position DAEWOO MATIZ 2003 Service Repair Manual

5B – 2 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FIVE-SPEED MANUAL TRANSAXLE
This five-speed transaxle assembly adopts the synchro-
nized mesh type of 5 forward speed. The reverse speed
gear is driven by sliding idle gear without synchronizer.
REVERSE GEAR MISSHIFT
PREVENTING MECHANISM
It prevents the gear from directly being shifted from 5th
to reverse when shifting to reverse from 5th. Shift to the
reverse in neutral position to prevent the shift cam from
being interfered to the shift guide bolt.
D103B001
In case of shifting to 5th gear, shift and select shaft ro-
tates to right that shift cam aparts from guide bolt and
moves upwards by returning spring. Therefore, shifting
to reverse in this condition is impossible because of in-
terference of guide bolt.
D103B002
When shifting to reverse from neutral position between
5th and reverse, shift cam rotates to left and shifting is
possible.
D103B003
DIFFERENTIAL
Differential is integrated with transmission case and
installed on chassis together with engine. It changes the
direction of power and increase torque by reducing
speed.
Reduction gear is installed parallel to counter shaft and
is helical gear type. Differential gear is bevel gear type
and is integrated with reduction gear.

FIVE-SPEED MANUAL TRANSAXLE 5B–11
DAEWOO M-150 BL2
D13B5031
6. Disconnect the radiator lower hose.

Remove the bolts (1).

Disconnect the radiator lower hose (2).
7. Remove crankshaft position (CKP) sensor.

Remove the bolt (3).

Disconnect the CKP sensor connector

Remove the CKP sensor.
D103B507
8. Disconnect the speedometer cable.

Loosen the nut (1).

Disconnect the cable (2).
9. Remove the vehicle speed sensor (VSS) if
equipped.

Disconnect VSS connector.

Remove the VSS.
D102E502
10. Remove the starter motor.

Remove upper two bolts that securing starter mo-
tor to transaxle.
D13B5041
11. Fix the engine assembly.

Remove the cowl panel weatherstrip.

Position the engine support fixture DW110–021
on the cowl panel and the front upper panel.

Tighten the engine fixture joint with a bolt after re-
moving exhaust manifold bolt (No.4).

FIVE-SPEED MANUAL TRANSAXLE 5B–13
DAEWOO M-150 BL2
D12B5731
20. Remove the front exhaust pipe.

Remove the front exhaust pipe nuts (exhaust
manifold side) (1).

Remove the gasket and separate exhaust man-
ifold pipe (2).

Make free the front exhaust pipe.
D13B5111
21. Support the transaxle with the transaxle remove/
install support DW220–030N.

Position the support on the jack (a).

Support the transaxle case and mount using a
jack and the transaxle remove/install support.
D103B512
22. Remove the transaxle lower bolt and nut.
a. Lower bolt.
b. Lower nut.
D13B5131
23. Remove the transaxle mount bolts.

5B–14 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B5141
24. Position the manual transaxle assembly in tilting.

To remove the manual transaxle side cover with-
out the interference with the front under longitudi-
nal panel (Left), tilt the engine/manual transaxle by
loosening the engine support fixture DW110– 021
joint with the wrench.
D13B5151
25. Remove the manual transaxle assembly.

Lower the transaxle assembly slowly by adjusting
jack.
a. Jack.
b. Transaxle assembly.

Tilt the transaxle assembly by adjusting jack.

Remove the transaxle assembly by pulling and
lowering it slowly.
D103B516
26. Support the engine to normal position using the en-
gine support fixture DW110–021.
Notice: The abnormal position of the engine may dam-
age to the related parts or interfere with them. You have
to support the engine to normal position when removing
the transaxle.
Important: If it is impossible to use the special tool, sup-
port the engine to normal position with the auto jack.
D13B5171
Installation Procedure
1. Install in the reverse order of removal.
2. Install the transaxle mounting bolts.
Tighten
Tighten the transaxle mounting bolts (body side) to
45–55 Nm (33–41 lb-ft).

5B–16 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B5032
8. Install the radiator lower hose and crank position
(CKP) sensor.
Tighten
Tighten the radiator lower hose bolt to 8–15 Nm
(70–132 lb-in).
Tighten the CKP sensor bolt to 5–8 Nm (44–70 lb-
in).
D13B520A
9. Refill the transaxle fluid.

Tighten the drain plug to 25–30 Nm (18–22 lb-ft)
(a).

Remove the oil level plug (1).

Refill recommended fluid to the proper level.
Classification 75W – 85 (GL–4) Capacity2.1L (2.21 qt)

Tighten the oil level plug to 36–54 Nm (26–40 lb-ft)
(b).
D13B521A
10. Adjust the clutch cable. Refer to Section 5C, Clutch.

Adjust the clutch cable by the clutch cable adjust
nut.
11. Install the transaxle under cover.
Tighten
Tighten the transaxle under cover bolts to 35–55
Nm (25–41 lb-ft).
D103B501
GEAR SHIFT CONTROL CASE
ASSEMBLY
Removal Procedure
1. Remove the air hose (air cleaner to throttle body).
Refer to Section 1B, SOHC Engine Mechanical.
2. Remove the battery.
3. Disconnect the select and the shift control cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and the shift control cable
(3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.

FIVE-SPEED MANUAL TRANSAXLE 5B–17
DAEWOO M-150 BL2
D103B522
4. Remove the select lever.

Remove the bolts (1).

Remove the select lever (2).
D103B523
5. Remove the shift interlock bolt.
Important: Certainly remove the shift interlock bolt.
Otherwise, the gear shift control case can not be re-
moved.
D103B524
6. Remove the gear shift control case assembly.

Remove the bolts (1).
Important: Make sure the gear shift lever is in NEU-
TRAL.

Remove the gear shift control case assembly (2).

Remove the gasket (3).
D103B525
7. Remove the shift lever.

Position the gear shift control case assembly to the
vice with a protector.

Remove the lever pin with a pin punch and a ham-
mer (1).

Remove the shift lever (2).

Remove the boot (3).

5B–22 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B540
Installation Procedure
1. Install in the reverse order of removal.
2. Push the cables toward the engine compartment
through dash panel’s hole slightly.
3. Position the cables on the select and the shift lever.
D13B5411
4. Connect the transaxle side select and shift control
cable.
5. Connect the gear shift lever side shift control cable.
6. Connect the gear shift lever side select control cable.

Insert the select control cable eye ring to the select
arm pin (1).

Install the selector lever control cable clip (2).

Install the select control cable to gear shift lever
bracket with E–ring (3).

Insert a driver to the select arm adjustment hole to
prevent the movement of gear shift lever in NEU-
TRAL (4).
7. Tighten the adjust nuts.
Tighten
Tighten the select cable adjust nut to 8–12 Nm
(71–106 lb-in).
D103B543
GEAR SHIFT CONTROL LEVER
Removal Procedure
1. Remove the floor console. Refer to Section 9G, Inte-
rior Trim.
2. Disconnect the select and shift control cable. Refer to
“Gear Shift control cable” in this section.
3. Remove the gear shift control lever assembly.

Remove the bolts (1).

Remove the gear shift control lever assembly (2).

Remove the gear shift lever sensor connector.
(If equipped with auto clutch).

5B–24 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
MAINTENANCE AND REPAIR
UNIT REPAIR
D13B701A
GEAR UNIT
Tools Required
09913–76010 Bushing, Seal Installer
DW09940–53111 Gear, Bearing Installer
DW09943–78210 Bushing, Seal Installer
DW220–010A Transaxle Fixture
KM519 Oil Seal Installer
Disassembly Procedure
1. Remove the manual transaxle. Refer to “Manual
Transaxle Assembly” in this section.
2. Position the manual transaxle to a transaxle stand us-
ing the transaxle fixture DW220–010.
D13B7021
3. Remove the related clutch parts. Refer to Section 5C,
Clutch.
4. Remove the manual transaxle mounting bracket.

Remove the bolts (1).

Remove the nut (2).

Remove the mounting bracket (3).
D103B703
5. Disconnect the backup light switch and speedometer
driven gear assembly.

Remove the nut (1).

Disconnect the backup light switch (2).

Remove the bolt (3).

Remove the speedometer driven gear assembly
(4).

FIVE-SPEED MANUAL TRANSAXLE 5B–33
DAEWOO M-150 BL2
D13B735A
13. Install the counter shaft bearing shim.

Measure clearance between the transaxle case
surface and the bearing outer race using a
straight ruler and gauge.

Select shim in order that clearance is within stan-
dard.
Unit : mm (in.)
Measured value (A) Shim thickness
0.33 − 0.37 (0.0130 – 0.0146) 0.45 (0.0177)
0.38 − 0.42 (0.0147 – 0.0165) 0.50 (0.0197)
0.43 − 0.47 (0.0169 – 0.0185) 0.55 (0.0217)
0.48 − 0.52 (0.0189 – 0.0205) 0.60 (0.0236)
0.53 − 0.57 (0.0209 – 0.0224) 0.65 (0.0256)
0.58 − 0.62 (0.0228 – 0.0244) 0.70 (0.0276)
0.63 − 0.67 (0.0248 – 0.0264) 0.75 (0.0295)
0.68 − 0.72 (0.0268 – 0.0283) 0.80 (0.0315)
0.73 − 0.77 (0.0287 – 0.0303) 0.85 (0.0335)
0.78 − 0.82 (0.0307 – 0.0323) 0.90 (0.0354)
0.83 − 0.87 (0.0327 – 0.0343) 0.95 (0.0374)
0.88 − 0.92 (0.0346 – 0.0362) 1.00 (0.0394)
0.93 − 0.97 (0.0366 – 0.0382) 1.05 (0.0413)
0.98 – 1.02 (0.0386 – 0.0402) 1.10 (0.0433)
1.03 – 1.07 (0.0406 – 0.0421) 1.15 (0.0453)
a. Straight ruler
b. Bearing outer race
c. Case surface
D13B736A
14. Install the side cover plate and the counter shaft fifth
gear.

Install the side cover plate (1).
Tighten
Tighten the screws to 6–7 N.m (53–62 lb–in).
Important: Use only new screws.

Install the counter shaft fifth gear (2).
Important: Position the machined boss side toward the
side cover plate.

5B–34 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B737A
15. Install the counter shaft fifth gear nut.

Shift the shift yoke using a screwdriver to engage
the first–gear and the third–gear or the second–
gear and the fourth–gear (1).
Tighten
Tighten the fifth gear nut to 60–80 Nm (44–59 lb-ft).

Caulk the nut using a chisel and a hammer (2).
D103B710
16. Install the input shaft fifth gear bearing and the fifth
gear / synchronizer ring.

Insert the bearing into the input shaft.

Install the fifth gear, wave spring and synchroniz-
er ring matching synchronizer’s oil groove and in-
put shaft punched mark (1).
D103B738
17. Install the fifth gear synchronizer hub assembly.

Install the synchronizer springs to hub (1).

Install the synchronizer key (2).
Important: In case of assembling synchronizer sleeve
and hub, let A=B.

Position the longer boss side of hub toward inner
side (3).

Position the chamfered spline of sleeve toward
inner side and install the hub to the sleeve (4).
D103B739
18. Install the fifth gear fork to the synchronizer hub as-
sembly.
19. Install the fifth gear fork and the synchronizer hub
assembly to the input shaft.
Important: Position the longer boss side of hub toward
inner side and match the synchronizer key and the hub
groove with the input shaft punched mark.