DAEWOO MATIZ 2003 Service Repair Manual

5B–46 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B780
9. Install the counter shaft left side bearing.

Install the left side bearing to the counter shaft us-
ing the gear, bearing installer DW09925–98221
and a hammer (1).
D103B765
10. Install the counter shaft right side bearing.
11. Install the gear unit. Refer to “Gear Unit” in this sec-
tion.
D103B781
GEAR SHIFT FORK
Disassembly Procedure
1. Remove the gear unit. Refer to “Gear Unit” in this
section.
2. Remove the each shift shaft assembly from the gear
unit.
3. Remove the first–second gear shift shaft assembly.

Fix the shift shaft assembly to a vise with protector.

Remove the first–second gear fork pin using a pin
punch and a hammer (1).

Remove the first–second gear shift fork (2).
D103B783

Remove the first–second gear shift yoke pin using
a pin punch and a hammer (3).

Remove the first–second gear shift yoke (4).
Important: Mark the place and direction of shift fork and
yoke to install easily before removing them.

FIVE-SPEED MANUAL TRANSAXLE 5B–47
DAEWOO M-150 BL2
D103B782
4. Disassemble the third–fourth gear shift shaft assem-
bly.

Fix the third–fourth gear shift shaft assembly to a
vise with protector.

Remove the third–fourth gear fork pin using a pin
punch and a hammer (1).

Remove the third–fourth gear fork (2).

Remove the third–fourth gear shift yoke pin using a
pin punch and a hammer (3).

Remove the third–fourth gear shift yoke (4).
D103B784
5. Disassemble the fifth–reverse gear shift shaft assem-
bly.

Remove the shift shaft not installed with yoke by
pushing (1).

Remove the following parts from the reverse shift
arm.
a. Fifth–reverse gear ball.
b. Reverse shift guide ball and spring.

Fix the shift shaft assembly to a vise with protector.

Remove the reverse gear shift arm pin using a pin
punch and a hammer (2).

Remove the reverse gear shift arm (3).
D103B785

Remove the fifth gear shift yoke pin using a pin
punch and a hammer (4).

Remove the fifth gear shift yoke (5).
D103B786
Inspection Procedure – Shift Shaft
1. Check for bent, deformed or damaged shift shaft.
2. Replace shift shaft if necessary.

5B–48 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B787
Inspection Procedure – Shift Fork
1. Measure the end thickness of shift fork and replace if
below limit.
Unit : mm (in.)


Shift fork end
thickness (mm)
Standard
Limit
Low Speed Shift Fork8.7 (0.343)8.1 (0.319)
High Speed Shift Fork7.8 (0.307)7.2 (0.283)
Fifth Gear Shift Fork7.8 (0.307)7.2 (0.283)
D103B788
Low Speed
Shift ShaftHigh Speed
Shift Shaft5th/Reverse
Shift Shaft
Assembly Procedure
1. Install in the reverse order of removal.
Important: Use only new fork fin and yoke pin.
D103B789
DIFFERENTIAL
Disassembly Procedure
1. Remove the differential assembly. Refer to “Gear
Unit” in this section.
2. Remove the differential ring gear.

Fix the differential assembly to a vise with protec-
tor.

Remove the bolts (1).

Remove the ring gear (2).
D103B790
3. Remove the pinion gear pin.

Remove the pin using a pin punch and a hammer
(1).

FIVE-SPEED MANUAL TRANSAXLE 5B–49
DAEWOO M-150 BL2
D103B791
4. Remove the pinion gear shaft.

Remove the shaft from the case (1).
D103B792
5. Remove the pinion gears and the side gears.

Remove the pinion gears and the washers (1).
Important: Remove the pinion gear and the washer by
rotating the side gear.

Remove the side gears (2).

Remove the adjust shims from the side gears (3).
D13B793A
6. Remove the differential right side bearing and
speedometer drive gear.

Remove the right side bearing using the differential
bearing puller DW220–020A–01 and the differen-
tial bearing plate adapter DW220–020A–02.

Remove the speedometer drive gear (1).
D13B794A
7. Remove the differential left side bearing.

Remove the left side bearing using the differential
bearing puller DW220–020A–01 and the differen-
tial bearing plate adapter DW220–020A–03.

5B–50 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B795
Side Gear Play Inspection
1. Measure the axle direction play of side gear and re-
place a side gear washer if it exceeds limit.
UNIT : mm (in.)


Thrust Free Play of
Differential Side

0.05–0.33
(0.0020–0.0130)
UNIT : mm (in.)
0.90 (0.0354) 0.95 (0.0374)
Thrust Adjusting 1.00 (0.0394) 1.05 (0.0413)

Thrust Adjusting
Shim
1.10 (0.0433) 1.15 (0.0453)
1.20 (0.0472)
D103B796
2. After checking for worn or scratched thrust adjusting
shim, replace it if necessary.
a. Side gear.
b. Driver.
D103B797
Assembly Procedure
1. Install the differential left side bearing.

Insert the left side bearing (1).

Install the left side bearing using the bushing, seal
installer 09913–76010 and a hammer.
Important: Coat the inner parts; bearing, washer, shim
etc. with gear fluid.
D103B798
2. Install the speedometer drive gear and differential
right side bearing.

Insert the speedometer drive gear(1).

Insert the differential right side bearing (2).

Install the right side bearing using the bushing,
seal installer 09913–76010 and a hammer.

FIVE-SPEED MANUAL TRANSAXLE 5B–51
DAEWOO M-150 BL2
D103B799
3. Install the side gears and the pinion gears.

Insert the trust adjusting shims to the side gears.

Install the side gears (1).

Install the pinion gears and washers (2).
Important: Install the pinion gears and washers simul-
taneously.
D103B800
4. Install the pinion gear shaft and pin.

Insert the shaft into the gear pin hole by rotating
(1).

Press the pin using a pin punch and a hammer (2).
Important: Use only new pin.
D13B801A
5. Install the differential ring gear.

Fix the differential assembly to a vise.

Install the ring gear with the bolts (1).
Tighten
Tighten the bolts to 80–100 Nm (59–74 lb-ft).
6. Install the differential assembly. Refer to “Gear Unit”
in this section.

5B–52 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
GeneralTypeForward gear–Synchronized
mesh type–
Reverse gear–Sliding mesh
type–
Gear ratio1st–3.818–
2nd–2.210–
3rd–1.423–
4th–1.029–
5th–0.837–
Reverse–3.583–
Final drive ratio–4.444–
Fluid capacityL(qt)2.1 (2.21)–
Fluid classification–75W-85 (GL-4)–
ServiceKey groove width of1st gearmm(in.)8.2 (0.323)8.6 (0.339)
synchronizer ring2nd, 3rd, 4th gearmm(in.)9.6 (0.378)10.0 (0.394)
5th gearmm(in.)9.4 (0.370)9.8 (0.386)
Shift fork end
thicknessLow speed shift fork
(1st~2nd)mm(in.)8.7 (0.343)8.1 (0.319)
High speed shift fork
(3rd~4th)mm(in.)7.8 (0.307)7.2 (0.283)
5th gear shift forkmm(in.)7.8 (0.307)7.2 (0.283)
Clearance between gear and synchronizer
ringmm(in.)1.0 (0.039)0.5 (0.020)
Clearance between sleeve and shift forkmm(in.)0.2 – 0.6
(0.008 – 0.024)1.0 (0.039)
Thrust free play of differential side gearmm(in.)0.05 – 0.33
(0.002 – 0.013)–
Speedometer gear ratio(Driven/Drive)–17/18 (0.944)–

FIVE-SPEED MANUAL TRANSAXLE 5B–53
DAEWOO M-150 BL2
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
5th/Reverse Gear Shift Shaft Bolt10 – 167 – 12–
Back Up Light Switch Nut15 – 1811 – 13–
Counter Shaft 5th Gear Nut60 – 8044 – 59–
Crankshaft Position Sensor Bolt5 – 8–44 – 70
Differential Ring Gear Bolt80 – 10059 – 74–
Engine Mounting Front Bracket Bolt
(Cylinder Block Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolt
(Crossmember Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolts
(Crossmember Side)45 – 5533 – 41–
Engine Mounting Front Damping Bush Bolt/Nut
(Bracket Side)68 – 8351 – 61–
Front Exhaust Pipe Nut
(Exhaust Manifold Side/Muffler Side)25 – 3518 – 25–
Gear Shift Control Case Bolt18 – 2813 – 21–
Gear Shift Lever Bolt4 – 7–35 – 62
High Speed Shift Shaft Bolt10 – 167 – 12–
Low Speed Shift Shaft Bolt10 – 167 – 12–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–
Radiator Lower Hose Bracket Bolts8 – 15–70 – 132
Reverse Idle Gear Shaft Bolt18 – 2813 – 21–
Reverse Shift Lever Bolt18 – 2813 – 21–
Select Cable Nut(Shift Lever Side)8 – 12–71 – 106
Select Lever Bolt18 – 2813 – 21–
Side Cover Plate Screw6 – 7–53 – 62
Shift Guide Bolt18 – 2813 – 21–
Shift Interlock Bolt18 – 2813 – 21–
Side Cover Bolt8 – 12–71 – 106
Speedometer Driven Gear Bolt4 – 7–35 – 62
Starter Motor Bolt18 – 2813 – 21–
Transaxle Case Bolt15 – 2211 – 16–
Transaxle Case(left) Cap Bolt8 – 12–71 – 106
Transaxle Lower Bolt and Nut(Engine Side)55 – 6541 – 48–
Transaxle Mounting Bolt(Body Side)45 – 5533 – 41–
Transaxle Mounting Bolt and Nut(Transaxle Side)55 – 6541 – 48–
Transaxle Upper Bolt(Engine Side)55 – 6541 – 48–
Transaxle Under Cover Bolt35 – 5525 – 41–

5B–54 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
SPECIAL TOOLS
SPECIAL TOOLS TABLE
D103B110
09913–76010
Bushing, Seal Installer
D103B106
DW09913–80112
Gear, Bearing Installer
D103B104
DW09921–57810
Gear, Bearing Remover
D103B107
DW09925–98221
Gear, Bearing Installer
D103B105
DW09940–53111
Gear, Bearing Installer
D103B109
DW09943–78210
Bushing, Seal Installer
D103B103
DW110–021
Engine Assembly
Support Fixture
D13B101A
DW220–010A
Transaxle Fixture

FIVE-SPEED MANUAL TRANSAXLE 5B–55
DAEWOO M-150 BL2
SPECIAL TOOLS TABLE (Cont’d)
D13B112A
DW220–020A–01
Differential Bearing
Puller
D13B113A
DW220–020A–02
Differential Bearing
Plate Adapter
D13B114A
DW220–020A–03
Differential Bearing
Plate Adapter
D103B102
DW220–031
Transaxle Remove/
Install Support
D103B108
KM466–A
Gear, Bearing Remover
/ Installer
D103B111
KM519
Oil Seal Installer