DAEWOO MATIZ 2003 Service Repair Manual

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–18 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B526
8. Remove the select/shift shaft.

Remove the shift guide bolt (1).

Remove the select/shift shaft (2).
D103B527
9. Remove the gear shift control case plate.

Remove the bolts (1).

Remove the Plate from the case (2).
D103B528
Inspection Procedure
1. Inspect for worn or damaged the fifth/reverse shift
cam (1).
2. Inspect for worn or damaged shift interlock plate (2).
3. Inspect for worn or damaged select/shift lever (3).
4. Inspect for bent or damaged select/shift shaft (4).
D13B529A
Installation Procedure
1. Install in the reverse order of removal.
2. Install the shift guide bolt.
Tighten
Tighten the shift guide bolt to 18–28 Nm (13–21 lb-ft).

FIVE-SPEED MANUAL TRANSAXLE 5B–19
DAEWOO M-150 BL2
D13B530A
3. Install the gear shift control case and the select lever.
Tighten

Tighten the gear shift control case bolts to 18–28
Nm (13–21 lb-ft).
a. Gear shift control case bolt.

Tighten the select lever bolts to 18–28 Nm (13–21
lb-ft).
b. Select lever bolt.
Important: Make sure a correct bolt. There is length dif-
ference between select lever bolts.
D13B531A
4. Install the shift interlock bolt.
Tighten
Tighten the shift interlock bolt to 18–28 Nm (13–21
lb-ft).
D103B532
SPEEDOMETER DRIVEN GEAR AND
CABLE
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the speedometer driven gear assembly.

Loosen the nut. (1).

Disconnect the cable (2).

Remove the bolt (3).

Remove the speedometer driven gear assembly
(4).
D103B533

Disconnect the vehicle speed sensor connector (If
equipped).
a. Vehicle speed sensor connector.

Disconnect the vehicle speed sensor.
b. Vehicle speed sensor.
Caution: Be careful to prevent personal injury while
the exhaust pipe is hot.

5B–20 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B534
2. Remove the battery. Refer to Section 1E, Engine
Electrical.
3. Disconnect the instrument cluster side cable. Refer to
Section 9E, Instrumentation/Driver Information.
4. Remove the speedometer cable.

Remove the cable grommet (1).

Pull out the speedometer cable from the dash pan-
el.
D103B535
Inspection Procedure
1. Remove the O–ring from the speedometer driven
gear housing.
2. Remove the driven gear pin and disconnect the driv-
en gear.

Check for a damaged or torn O–ring.

Check for a worn or damaged tooth of driven gear.
a. O–ring.
b. Driven gear pin.
c. Driven gear.
D103B536
Installation Procedure
1. Install in the reverse order of removal.
Important: Install the speedometer driven gear assem-
bly after connecting the speedometer cable with the
speedometer driven gear assembly completely.
D13B537A
2. Install the speedometer driven gear assembly to
transaxle housing.
Tighten
Tighten the speedometer driven gear assembly bolt
to 4–7 Nm (35–62 lb-in).

FIVE-SPEED MANUAL TRANSAXLE 5B–21
DAEWOO M-150 BL2
D103B501
GEAR SHIFT CONTROL CABLE
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 transaxle side select and shift control
cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and shift control cable (3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.
D19E573A
4. Remove the floor console. Refer to Section 9G, Inte-
rior Trim.

Put aside the floor carpet in order to get the gear
shift cable shown.
D13B5381
5. Disconnect the gear shift lever side select and shift
control cable.

Remove the select control cable clip (1).

Ply off the eye ring (2).

Remove the select control cable E–ring (3).

Disconnect the select control cable (4).

Remove the shift control cable pin (5).

Remove the shift control cable E–ring (6).

Ply off the shift control cable (7).
D13B539A
6. Remove the select and shift control cable.

Remove the nuts (1).

Pull the cables out in the passenger room.

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).

FIVE-SPEED MANUAL TRANSAXLE 5B–23
DAEWOO M-150 BL2
D13B544A
Installation Procedure
1. Install in the reverse order of removal.
2. Install the gear shift control lever assembly.
Tighten
Tighten the bolts to 4–7 Nm (35–62 lb-in).
3. Adjust the select cables. Refer to “Gear Shift Control
Cable” in this section.

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–25
DAEWOO M-150 BL2
D103B704
6. Remove the select lever.

Remove the bolt (1).

Remove the select lever (2).
D103B705
7. Remove the gear shift control case assembly.

Remove the bolts (1).

Remove the shift interlock bolt (2).
Important: Certainly remove the shift interlock bolt.
Otherwise, gear shift control case can not be removed.

Remove the gear shift control case assembly (3).

Remove the gasket (4).
D103B706
8. Remove the side cover.

Remove the bolts (1).

Remove the side cover using a rubber hammer (2).

Remove the sealant on the side cover and the
transaxle case.
D103B707
9. Remove the fifth–gear shift fork guide ball, the snap
ring and the input shaft fifth–gear snap ring.

Remove the fifth–gear shift fork plug (1).

Remove the guide ball using a magnet.

Remove the fifth–gear shift fork snap ring (2).

Remove the fifth–gear snap ring (3).

Remove the fifth–gear synchronizer plate.