DAEWOO MATIZ 2003 Service Repair Manual

5B–26 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B708
10. Remove the fifth–gear shift fork pin.

Shift the shift fork to the fifth–gear.

Remove the fork pin using a pin punch and a
hammer (1).
D103B709
11. Remove the input shaft fifth–gear fork and synchro-
nizer hub assembly.

Pull and remove the fork and the hub assembly
together (1).

Remove the sleeve, key and spring from the syn-
chronizer hub assembly.
D103B710
12. Remove the input shaft fifth–gear, the synchronizer
ring and the fifth–gear bearing.

Pull and remove the fifth–gear, wave spring and
synchronizer ring together (1).

Remove the fifth–gear bearing.
D103B711
13. Remove the countershaft fifth–gear.

Shift the shift yoke using a driver to engage the
first–gear and the third–gear or the second–gear
and the fourth–gear (1).

Remove the caulking and the nut. (2, 3)

FIVE-SPEED MANUAL TRANSAXLE 5B–27
DAEWOO M-150 BL2
D103B712

Remove the counter shaft fifth–gear (4).
D103B713
14. Remove the side cover plate and the counter shaft
bearing shim.

Remove the screws (1).

Remove the side cover plate (2).

Remove the counter shaft bearing shim.
D103B714
15. Remove the shift shaft spring and ball.

Remove the bolt and remove the fifth–reverse
gear shift shaft spring and ball (1).

Remove the bolt and remove the third–fourth
gear shift shaft spring and ball (2).

Remove the bolt and remove the first–second
gear shift shaft spring and ball (3).
Important: There is difference between the fifth–re-
verse gear shift shaft spring and the others. Mark it to
distinguish easily when installing.
D103B715
16. Remove the reverse idle gear shaft bolt.
Important: The case (Left) can not be removed without
removing the reverse idle gear shaft bolt.

5B–28 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B716
17. Remove the transaxle case (Left).

Remove the bolts from the left side case (1).

Remove the bolts, stud bolts if equipped with
auto clutch.

Remove the bolts from the right side of case (2).

Remove the left side case by hitting with a rubber
hammer lightly.

Remove the sealant on the case.
D103B717
18. Remove the reverse gear shift lever.

Remove the bolts (1).

Remove the reverse gear shift lever (2).
D103B718
19. Remove the reverse idle gear shaft assembly.

Push the reverse idle gear toward inner case.

Pulling shaft and remove the reverse idle gear
and shaft (1).

Remove the reverse idle gear from the shaft.
D103B719
20. Remove the fifth–reverse gear shift shaft.
a. Fifth–reverse gear shift shaft.

FIVE-SPEED MANUAL TRANSAXLE 5B–29
DAEWOO M-150 BL2
D103B720
21. Remove the gear unit.

Remove the gear unit and the shift shaft assem-
bly together (1).
Notice: Be careful not to damage teeth of the counter
shaft pinion and the differential ring gear.

Remove the high and the low speed shift shaft
assembly from the gear unit.
D103B721
22. Remove the differential assembly.

Insert a wooden stick into the lower side of differ-
ential (1).

Remove the differential assembly by moving it
right and left (2).
D103B722
23. Remove the related parts of the transaxle case (Left
Side).

Remove the bolt (1).

Remove the oil gutter (2).

Remove the bolts (3).

Remove the oil plate (4).

Remove the differential left side oil seal using a
hammer and a copper chisel (5).
D103B723

Remove the bolts (6).

Remove the case cap (Left Side) (7).

Remove the case cap O–ring (Left Side) (8).

Remove the oil level plug (including steel gasket)
(9).

Remove the counter shaft bearing outer race us-
ing a hammer and the gear, bearing installer DW
09940–53111.

5B–30 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B724
24. Remove the related parts of the transaxle case
(Right Side).

Remove the input shaft oil seal using a screwdriv-
er (1).

Remove the differential left side oil seal using a
hammer and a copper chisel (2).
D103B725
Synchronizer Sleeve and Shift Fork
Inspection
1. Measure the clearance between synchronizer sleeve
and shift fork and if the clearance exceeds the limit,
replace the shift fork.
Unit : mm (in.)

Clearance Between
Standard Limit

Clearance Between
Sleeve and Shift
Fork
0.2 ∼0.6
(0.008∼0.024)1.0
(0.039)
D103B726
Assembly Procedure
1. Install the related parts of the transaxle case (Right
Side).

Install the input shaft oil seal using the bushing
seal installer DW09943–78210.

Install the differential right side oil seal using the
bushing, seal installer 09913–76010.
Important: Use only a new oil seal.
Important: Coat the transaxle inner parts with gear fluid
when installing.
D13B727A
2. Install the related parts of the transaxle case (Left
Side).

Install the oil plate with the bolts.

Install the oil gutter with the bolt.

Install the oil level plug (including steel gasket).
a. Oil level plug.
Tighten
Tighten the oil level plug to 36–54 Nm (26–40 lb-ft).

Install the left side case cap with the bolts (includ-
ing O–ring) (1).

FIVE-SPEED MANUAL TRANSAXLE 5B–31
DAEWOO M-150 BL2
D13B727A
Tighten
Tighten the bolt to 8–12 Nm (71–106 lb-in).
b. Case cap retaining bolt.

Install the differential left side oil seal using the oil,
seal installer KM519.
D103B728
3. Install the differential assembly to the right side of
transaxle case.
a. Differential assembly.

When the differential ring gear surface is lower
than the right side of transaxle case surface, it is
installed correctly.
D103B729
4. Install the low and the high speed shift shaft assem-
bly to the gear unit.
5. Install the gear unit.

Push the gear unit by matching it with the input and
the counter shaft hole (1).
Notice: Be careful not to damage teeth of the counter
shaft pinion and the differential ring gear.
D13B730A
6. Install the fifth–reverse gear shift shaft.
7. Install the reverse idle gear shaft assembly and the
reverse gear shift lever.

Install the reverse idle gear shaft assembly (1).
Important: Match the marking of the reverse idle gear
shaft bolt hole with the protrusion of the transaxle case
(Right Side).

Install the reverse gear shift lever (2).
Tighten
Tighten the bolts to 18–28 Nm (13–21 lb-ft).

5B–32 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B731A
8. Install the shift shaft ball and spring.

Install the third–fourth gear shift shaft ball and
spring.
Tighten
Tighten the bolt to 10–16 Nm (7–12 lb-ft) (a).

Install the fifth–reverse gear shift shaft ball and
spring.
Tighten
Tighten the bolt to 10–16 Nm (7–12 lb-ft) (b).
Important: Install the fifth–reverse gear shift shaft
spring marked when removing.
D13B732A
9. Install the transaxle left side case.

Coat the transaxle case with recommended seal-
ant.
Transaxle Case Sealant THREE BOND 1215

Install the transaxle left side case to the transaxle
right side case.
Tighten
Tighten the bolts to 15–22 Nm (11–16 lb-ft) (a).

Tighten the bolts (8), stud bolts (3) if equipped with
auto clutch.
Tighten the bolts to 15–22 Nm (11–16 lb-ft) (b).
D13B733A
10. Install the first–second gear shift shaft ball and
spring.
Tighten
Tighten the bolt to10–16 Nm (7–12 lb-ft) (a).
11. Install the reverse idle gear shaft bolt.
Tighten
Tighten the bolt to 18–28 Nm (13–21 lb-ft) (b).
D103B734
12. Install the counter shaft bearing outer race.

Install the counter shaft bearing outer race using
the gear, bearing installer DW09940–53111.
a. Bearing outer race.
Important: Check if the bearing and the outer race are
correctly installed by rotating counter shaft.

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.

FIVE-SPEED MANUAL TRANSAXLE 5B–35
DAEWOO M-150 BL2
D103B740
20. Install the fifth gear shift fork pin.

Push the shift fork toward the fifth gear.

Install the shift fork pin using a pin punch and a
hammer(1).
Important: Use only new shift fork pin.
D103B741
21. Install the input shaft fifth gear snap ring, the fifth
gear shift fork snap ring and guide ball.

Install the fifth gear synchronizer plate.

Install the fifth gear snap ring (1).

Install the fork snap ring (2).
Important: Use only new snap ring.

Tighten the fork plug after inserting the guide ball
into the fork hole.
D13B742A
22. Install the side cover(1).

Coat the side cover with recommended sealant.
Side Cover Sealant THREE BOND 1215
Tighten
Tighten the side cover bolts to 8–12 Nm (71–106
lb-in).
D13B743A
23. Install the gear shift control case assembly.

Install the case gasket.

Install the gear shift control case.
Tighten

Tighten the bolts to 18–28 Nm (13–21 lb-ft) (a).

Tighten the shift interlock bolt to 18–28 Nm (13–
21 lb-ft) (b).

Install the select lever.
Tighten
Tighten the bolts to 18–28 Nm (13–21 lb-ft) (c).