DAEWOO NUBIRA 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 131
DAEWOO V–121 BL4
69. Using a chisel and hammer, unstake and remove
the spacer.
70. Using a pin punch and hammer, drive out the pin.
71. Remove the manual valve lever shaft and manual
valve lever.
72. Remove the parking lock rod from the manual valve
lever.

5A2 – 132IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
73. Using a screwdriver, remove the oil seal.
74. Using brake spring compressor bolt/nut
DW240–060–01, 1st & reverse brake adapter
DW240–070 and planetary ring gear remover
DW240–090, remove the planetary ring gear.
75. Install the 3 bolts to the counter drive gear.
S Bolt (M6) : L= 40–80mm, Pich = 1.0mm
76. Rotate 3 bolts in order and remove the counter
drive gear and planetary ring gear.
WARNING : USE CAUTION WHEN REMOVING SNAP
RINGS OR PERSONAL INJURY MAY RESULT.
77. Using brake spring compressor bolt/nut
DW240–060–01 and 1st & reverse brake adapter
DW240–070, remove the snap ring of 1st & reverse
brake.

AISIN AUTOMATIC TRANSAXLE 5A2 – 133
DAEWOO V–121 BL4
78. Remove the flange, 4 discs, 4 plates and return
spring.
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
Notice : Blowing off the air may cause the piston’s jump–
out. When removing the piston, hold it with your hand us-
ing a waste cloth.
Notice : Take care not to splash ATF when air–blowing
79. Apply 392 kPa (57 psi) of compressed air to the
transaxle case to remove the 1st & reverse brake
piston.
80. Remove the 2 O–rings from the 1st & reverse
brake piston.
81. Remove the bolt and No.1 transaxle case plate
from the transaxle case.

5A2 – 134IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
82. Using a suitable puller, remove the counter driven
gear outer tapered roller bearing race and shim
from the transaxle case.
83. Using a driver, remove the oil seal from the trans-
axle case.
Notice : Be careful not to damage the transaxle case
when removing the oil seal using a driver.
84. Using transaxle case side bearing outer race adapt-
er DW240–150 and adapter handle DW240–170,
remove the transaxle case side bearing outer race
and shim.
85. Remove the 3 bolts and oil reservoir lock plate from
the transaxle housing.
86. Remove the bolt and No.1 transaxle apply pipe
clamp from the transaxle housing.
87. Remove the transaxle lube apply pipe and differen-
tial gear lube apply pipe from the transaxle housing.

AISIN AUTOMATIC TRANSAXLE 5A2 – 135
DAEWOO V–121 BL4
88. Using a suitable puller, remove the counter driven
gear outer tapered roller bearing race from the
transaxle housing.
89. Using a driver, remove the oil seal from the trans-
axle housing.
Notice : Be careful not to damage the transaxle housing
when removing the oil seal using a driver.
90. Using a suitable puller, remove the side bearing
outer race from the transaxle housing.
WARNING : USE CAUTION WHEN REMOVING SNAP
RINGS OR PERSONAL INJURY MAY RESULT.
Notice : Stop the press when the O/D brake piston is low-
ered 1–2 mm (0.039–0.078 in.) from the snap ring groove,
preventing the O/D brake piston from being deformed.
91. Using brake/clutch spring compressor DW240–020,
overdrive brake adapter DW240–050 and a driver,
remove the snap ring.
92. Remove the O/D brake return spring.

5A2 – 136IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
Notice : Blowing off the air may cause the piston’s jump–
out.When removing the piston, hold it with your hand using
a waste cloth.
Notice : Take care not to splash ATF when air–blowing.
93. Apply 392 kPa (57 psi) of compressed air to the
transaxle rear cover to remove the O/D brake pis-
ton.
94. Remove the 2 O–rings from the O/D brake piston.
95. Remove the 2 seal rings from the transaxle rear
cover.
Notice : Do not expand the seal ring excessively.
96. Remove the 4 screw plugs and 4 O–rings from the
transaxle rear cover.

AISIN AUTOMATIC TRANSAXLE 5A2 – 137
DAEWOO V–121 BL4
MAJOR COMPONENT ASSEMBLY
Tools Required
DW240–020 Brake/Clutch Spring Compressor
DW240–050 Overdrive Brake Adapter
DW240–060–01 Brake Spring Compressor Bolt/Nut
DW240–060–02 Brake Spring Compressor Plate
DW240–070 1st / Reverse Brake Adapter
DW240–100 Counter Drive Gear Installation Adapter
DW240–130 Differential Preload Adapter
DW260–031–01 Transaxle Housing Oil Seal Installer
DW260–031–02 Transaxle Case Oil Seal Installer
DW260–041 Planetary Ring Gear Nut Removal/Installa-
tion Socket
DW240–160 Transaxle Case Outer Tapered Roller Bear-
ing Race Adapter
DW240–140 Transaxle Housing Side Bearing Outer Race
Adapter
DW240–170 Adapter Handle
Assembly Procedure
1. Install 4 new O–rings to the 4 screw plugs.
2. Install the 4 screw plugs with the O–rings to the
transaxle rear cover.
Tighten
Tighten the screw plugs to 7.4 NSm (65 lb–in).
3. Install the 2 seal rings to the transaxle rear cover.
4. Using the vernier calipers, measure the free length
of the O/D brake piston return spring together with
the spring seat.
S Standard free length : 18.99 mm (0.7476 in.)

5A2 – 138IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
5. Coat 2 new O–rings with ATF, install them to the
O/D brake piston.
6. Coat the O/D brake piston with ATF, install it to the
transaxle rear cover.
Notice : Be careful not to damage the O–rings of the O/D
brake piston.
7. Using brake/clutch spring compressor DW240–020,
overdrive brake adapter DW240–050 and a driver,
install the O/D brake return spring and snap ring to
the transaxle rear cover.
Notice : Stop the press when the O/D brake piston is low-
ered 1–2 mm (0.039
0.078 in.) from the snap ring groove,
preventing the O/D brake piston from being deformed.
8. Using transaxle housing side bearing outer race
adapter DW240–140 and adapter handle
DW240–170, install a new side bearing outer race
into the transaxle housing.

AISIN AUTOMATIC TRANSAXLE 5A2 – 139
DAEWOO V–121 BL4
9. Using transaxle housing oil seal installer
DW260–031–01 and a hammer, drive in a new
transaxle housing oil seal.
S Oil seal in depth: 3.1mm (0.122 in.)
10. Install a new outer tapered roller bearing race into
the transaxle housing.
Notice : Press
fit the outer tapered roller bearing race un-
til it contacts the transaxle housing.
11. Install the transaxle lube apply pipe and differential
gear lube apply pipe to the transaxle housing.
12. Install the No.1 transaxle apply pipe clamp to the
transaxle housing with the bolt.
Tighten
Tighten the bolt to 5.4 NSm (48 lb–in).
13. Install the oil reservoir lock plate to the transaxle
housing with the 3 bolts.
Tighten
Tighten the bolts to 5.4 NSm (48 lb–in).

5A2 – 140IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
14. Install the shim to the transaxle case.
Notice : First install a shim of the same thickness as be-
fore.
15. Install a new bearing outer race into the transaxle
case.
16. Using transaxle case oil seal installer
DW260–031–02 and a hammer, drive in a new
transaxle case oil seal.
S Oil seal in depth: 4.3 mm (0.169 in.)
17. Install the shim to the transaxle case.
Notice : First install a shim of the same thickness as be-
fore.
18. Using transaxle case outer tapered roller bearing
race adapter DW240–160 and adapter handle
DW240–170, press in a new outer tapered roller
bearing race into the transaxle case.
Notice : Press–fit the shim until it contacts the transaxle
case.
19. Install the No.1 transaxle case plate to the trans-
axle case with the bolt.
Tighten
Tighten the bolt to 9.8 NSm (87 lb–in).