DAEWOO MATIZ 2003 Service Repair Manual

PARKING BRAKE 4G–5
DAEWOO M-150 BL2
D17D504A
Installation Procedure
1. Install the parking brake lever with the cotter pin, pin,
bolts, and nut.
Tighten

Tighten the parking brake nut to 10 Nm (89 lb-in)
(1).

Tighten the parking brake bolts to 10 Nm (89 lb-in)
(2).
2. Connect the brake warning lamp switch.
3. Install the brake warning lamp switch screw.
4. Install the parking brake cable cover. Refer to Section
9G, Interior Trim.
5. Install the parking brake lever cover. Refer to Section
9G, Interior Trim.
D107D505
PARKING BRAKE WARNING LAMP
SWITCH
Removal Procedure
1. Remove the gear shift lever cover. Refer to Section
5B, Five–Speed Manual Transaxle.
2. Remove the parking brake warning lamp switch.

Disconnect the parking brake warning lamp switch
(1).
D107D506

Apply the parking brake (2).

Remove the parking brake warning lamp switch
carefully (3).
D107D507
Installation Procedure
1. Install the parking brake warning lamp switch.
2. Release the parking brake.
3. Connect the parking brake warning lamp switch.
4. Install the gear shift lever cover. Refer to Section 5B,
Five–Speed Manual Transaxle.

4G–6 PARKING BRAKE
DAEWOO M-150 BL2
D107D508
PARKING BRAKE CABLE
Removal Procedure
1. Remove the parking brake lever. Refer to “Parking
Brake Lever” in this section.
2. Remove the parking brake cable.

Remove the cable pulley (1).

Loosen the adjustment nuts (2).

Remove the strengthener (3).
D107D509

Remove the grommet (4).
D107D510
3. Remove the rear brake drum assembly. Refer to Sec-
tion 2D, Rear Suspension.
4. Disconnect the parking brake cable from the rear
brake drum assembly.

Remove the clip from the brake plate (1).

Disconnect the parking brake cable from the trailing
shoe (2). Refer to Section 4E, Rear Drum Brake.
D107D511
5. Remove the parking brake cable.

Remove the clamp bolts fastening the brake cable
(RH Rear Brake Side) (1).

Remove the fuel filter. Refer to Section 1F, Engine
Controls.

PARKING BRAKE 4G–7
DAEWOO M-150 BL2
D107D512

Remove the clamp bolts fastening the brake cable
(LH Rear Brake Side) (2).
D17D513A
D17D514A
Installation Procedure
1. Install the fuel filter.
2. Install the parking brake cable with the clamp bolts.
Tighten
Tighten the parking brake cable clamp bolts to 10 Nm
(89 lb-in) (1, 2).
D17D515A
3. Connect the parking brake cable to the rear brake
drum assembly. Refer to Section 4E, Rear Drum
Brake.
4. Install the rear brake drum assembly. Refer to Sec-
tion 2D, Rear Suspension.
5. Install the grommet and the strengthener.
6. Install the cable pulley with the adjustment nuts.
Tighten
Tighten the adjustment nuts to 10 Nm (89 lb-in) (3).
7. Install the parking brake lever. Refer to “Parking Brake
Lever” in this section.

4G–8 PARKING BRAKE
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Description
Parking Brake Lever Notch Number

5–7 (Loaded 44.1 lb)
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Parking Brake Cable Clamp Bolts 10 – 89
Parking Brake Lever Bolts 10 – 89
Parking Brake Lever Nut 10 – 89
Parking Brake Cable Adjusting Nuts 10 – 89

PARKING BRAKE 4G–9
DAEWOO M-150 BL2
SCHEMATIC AND ROUTING DIAGRAMS
PARKING BRAKE SYSTEM
D17A201B

DAEWOO M-150 BL2

SECTION 5B
FIVE-SPEED MANUAL TRANSAXLE
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.
TABLE OF CONTENTS
Description and Operation 5B-2. . . . . . . . . . . . . . . . . .
Five-Speed Manual Transaxle 5B-2. . . . . . . . . . . . . . .
Reverse Gear Misshift Preventing
Mechanism 5B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential 5B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locators 5B-3. . . . . . . . . . . . . . . . . . . . . . .
Gear Shift Control 5B-3. . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft and Counter Shaft Gear 5B-4. . . . . . . . . .
Gear Shift Fork 5B-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential and Case 5B-7. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 5B-8. . . . . . .
General Diagnosis 5B-8. . . . . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 5B-9. . . . . . . . . . . . . . . . . . . . . . .
Changing Fluid 5B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Transaxle Noise 5B-9. . . . . . . . . . . . . . . . . .
Checking Bearing Noise 5B-9. . . . . . . . . . . . . . . . . . . .
Repair Instruction 5B-10. . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 5B-10. . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transaxle Assembly 5B-10. . . . . . . . . . . . . . .
Gear Shift Control Case Assembly 5B-17. . . . . . . . . .
Speedometer Driven Gear and Cable 5B-19. . . . . . .
Gear Shift Control Cable 5B-21. . . . . . . . . . . . . . . . . .
Gear Shift Control Lever 5B-23. . . . . . . . . . . . . . . . . . .
Unit Repair 5B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Unit 5B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft 5B-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter Shaft 5B-41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Shift Fork 5B-46. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential 5B-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 5B-52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5B-52. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5B-53. . . . . . . . . .
Special Tools 5B-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5B-54. . . . . . . . . . . . . . . . . . . . . . .

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–3
DAEWOO M-150 BL2
COMPONENT LOCATORS
GEAR SHIFT CONTROL

D13B4011
1 Gear Shift Control Lever Knob
2 Gear Shift Cable Bracket
3 Select Cable
4 Shift Cable5 Select Arm
6 Gear Shift Control Lever
7 Gear Shift Control Lever Guide

5B–4 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
INPUT SHAFT AND COUNTER SHAFT GEAR
D13B4031

FIVE-SPEED MANUAL TRANSAXLE 5B–5
DAEWOO M-150 BL2
1 Input Shaft Circlip
2 5th Gear Synchronizer Plate
3 5th Gear Synchronizer Sleeve
4 5th Gear Synchronizer Spring
5 5th Gear Synchronizer Key
6 5th Gear Synchronizer Hub
7 5th Gear Synchronizer Ring
7-1 Wave Spring
8 Input Shaft 5th Gear
9 Input Shaft 5th Gear Bearing
10 Input Shaft 5th Gear Spacer
11 Input Shaft Bearing(Left)
12 Input Shaft 4th Gear
13 4th Gear Synchronizer Ring
13-1 Wave Spring
14 Input Shaft 4th Gear Bearing
15 3rd-4th Gear Synchronizer Sleeve
16 3rd-4th Gear Synchronizer Spring
17 3rd-4th Gear Synchronizer Key
18 3rd-4th Gear Synchronizer Hub
19 3rd Gear Synchronizer Ring
20 Input Shaft 3rd Gear
21 Input Shaft 3rd Gear Bearing
22 Input Shaft
23 Input Shaft Bearing(Right)24 Input Shaft Oil Seal
25 Reverse Gear Shaft Bolt
26 Reverse Gear Shaft
27 Reverse Idle Gear
28 Counter Shaft Nut
29 Counter Shaft 5th Gear
30 Counter Shaft Bearing Shim
31 Counter Shaft Bearing(Left)
32 Counter Shaft 4th Gear
33 Counter Shaft 3rd-4th Gear Spacer
34 Counter Shaft 3rd Gear
35 Counter Shaft 2nd Gear
36 2nd Gear Synchronizer Ring
37 Counter Shaft 2nd Gear Bearing
38 1st-2nd Gear Synchronizer Circlip
39 1st-2nd Gear Synchronizer Sleeve
40 1st-2nd Gear Synchronizer Spring
41 1st-2nd Gear Synchronizer Key
42 1st-2nd Gear Synchronizer Hub
43 1st Gear Synchronizer Ring
44 Counter Shaft 1st Gear
45 Counter Shaft 1st Gear Bearing
46 Counter Shaft
47 Counter Shaft Bearing(Right)