DAEWOO NUBIRA 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 151
DAEWOO V–121 BL4
63. Install the flange, 2 discs and 2 plates.
S Install in order : F
D
P
D
P
(D = Disc, P = Plate, F = Flange)
64. Install the 2nd brake return spring.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
65. Coat 2 new O–rings with ATF, install them to the
2nd brake piston.
66. Install the 2nd brake piston into the 2nd brake
clutch cylinder.
Notice : Be careful not to damage the O–rings.
67. Install the 2nd brake clutch cylinder to the transaxle
case.

5A2 – 152IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
68. Using brake spring compressor bolt / nut
DW240–060–01 and 2nd brake adapter
DW240–080, compress the 2nd brake piston return
spring.
69. Using a screwdriver, install the snap ring.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
70. Coat the thrust bearing race with petroleum jelly
and install it onto the front planetary sun gear.
S Race:
Inner diameter: 19.3 mm (0.760 in.)
Outer diameter : 29.0 mm (1.142 in.)
71. Install the front planetary sun gear to the transaxle
case.
72. Install the thrust washer and one–way clutch as-
sembly to the rear planetary sun gear.

AISIN AUTOMATIC TRANSAXLE 5A2 – 153
DAEWOO V–121 BL4
73. Coat the thrust bearing race with petroleum jelly
and install it onto the rear planetary sun gear and
one–way clutch assembly.
S Bearig:
Inner diameter: 42.5 mm (1.673 in.)
Outer diameter: 57.5 mm (2.264 in.)
Notice : Check the direction of the bearing.
74. Install the rear planetary sun gear and one–way
clutch assembly to the transaxle case.
75. Coat the thrust bearing race with petroleum jelly
and install it onto the transaxle case.
S Race:
Inner diameter: 34.95 mm (1.3760 in.)
Outer diameter: 45.50 mm (1.7913 in.)
Notice : Check the direction of race.
76. Coat the thrust needle roller bearing with petroleum
jelly and install it onto the forward clutch hub.
S Bearig:
Inner diameter: 33.3 mm (1.311 in.)
Outer diameter: 46.5 mm (1.831 in.)
Notice : Check the direction of bearing.

5A2 – 154IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
77. Install the forward clutch hub to the transaxle case.
78. Coat the thrust bearing race with petroleum jelly
and install it onto the forward clutch hub.
S Race:
Inner diameter: 19.3 mm (1.760 in.)
Outer diameter: 30.6 mm (1.205 in.)
79. Install the thrust bearing race and thrust needle roll-
er bearing to the forward & reverse clutch assem-
bly.
S Race and bearing diameter: mm(in.)
Inner diameterOuter diameter
Race18.1 (0.713)28.2 (1.110)
Bearing18.1 (0.713)29.6 (1.165)
80. Install the forward & reverse clutch assembly to the
transaxle case.

AISIN AUTOMATIC TRANSAXLE 5A2 – 155
DAEWOO V–121 BL4
81. Check to see if the sliding surface of the disc, plate
and flange of 2nd coast & O/D brake are worn or
burnt. If necessary, replace them.
Notice : If the lining of the disc is peeling off or discolored,
or even if a part of the printed mark is defaced, replace all
discs.
Notice : Before assembly new discs, soak them in ATF for
at least 15 minutes.
82. Using a screwdriver, install the snap ring to the
transaxle case.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
83. Install the flange, 2 discs and 2 plates to the trans-
axle case.
S Install in order: P
D
P
D
F
(P = Plate, D = Disc, F = Flange)
84. Clean the connected part the transaxle case and
transaxle rear cover.
85. As shown in the illustration, place a straight edge
on the transaxle case and measure the distance
between the 2nd coast & O/D brake flange and
straight edge using vernier calipers. (Dimension A).

5A2 – 156IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
86. As shown in the illustration, place a straight edge
on the O/D brake piston and measure the distance
between the transaxle rear cover and straight edge
using vernier calipers. (Dimension B).
87. Calculate the piston stroke value using the following
formula. Select a flange which satisfies the piston
stroke value and install it.
Piston stroke = Dimension A
Dimension B
Piston stroke : 0.65
1.05 mm (0.0256
0.0413
in.)
S Flange thickness : mm (in.)
Piston stroke
value
ThicknessMark
0.738 ~ 0.949
(0.02905 ~
0.03736)3.0
(0.118)0
0.950 ~ 1.149
(0.03740 ~
0.04524)3.2
(0.126)1
1.150 ~ 1.349
(0.04528 ~
0.05311)3.4
(0.134)2
1.350 ~ 1.549
(0.05315 ~
0.06098)3.6
(0.142)3
1.550 ~ 1.702
(0.06102 ~
0.06701)3.8
(0.150)0
88. Install new 4 apply gaskets to the transaxle rear
cover.
89. Coat the thrust neddle roller bearing with petroleum
jelly and install it onto the forward & reverse clutch
assembly.
S Bearig:
Inner diameter: 43.2 mm (1.701 in.)
Outer diameter: 62.0 mm (2.441 in.)
90. Remove any packing material and be careful not to
get oil on the contacting surfaces of the transaxle
rear cover or transaxle case.

AISIN AUTOMATIC TRANSAXLE 5A2 – 157
DAEWOO V–121 BL4
91. Apply formed in place gasket (FIPG) to the trans-
axle rear cover.
FIPG: three bond 1281 or equivalent
Seal bend width: 1.2 mm (0.047 in.)
92. Install the transaxle rear cover to the transaxle case
with the 9 bolts.
Tighten
Tighten the bolts to 25 NSm (18 lb–ft).
93. Install the counter driven gear assembly to the
transaxle case.
94. Install the differential gear assembly to the trans-
axle case.

5A2 – 158IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
95. Install the direct clutch hub to the transaxle case.
96. Install the thrust bearing race and thrust needle roll-
er bearing to the transaxle case.
S Race and bearing: mm (in.)
Inner diameterOuter diameter
Race20.5 (0.807)32.6 (1.283)
Bearing17.8 (0.701)30.2 (1.189)
97. Install the direct clutch assembly to the transaxle
case.
98. Install new apply gasket.

AISIN AUTOMATIC TRANSAXLE 5A2 – 159
DAEWOO V–121 BL4
99. Install the thrust needle roller bearing to the trans-
axle case.
Notice : Check the direction of the bearing.
100. Place the oil pump through the input shaft, and
align the bolt holes of the oil pump with the trans-
axle case.
101. Install the 6 oil pump bolts.
Tighten
Tighten the bolts to 25 NSm (18 lb–ft).
102. Measure the end play in axial direction.
Notice : If the end play is not as specified, select and re-
place the thrust needle roller bearing.
S End play 0.3
0.9 mm (0.012
0.035 in.)
S Bearing: mm (in.)
Inner diameter
Outer
diameterThichness
32.5 (1.280)48.5 (1.909)4.21 (0.1657)
32.9 (1.295)48.5 (1.909)3.62 (0.1425)
103. Make sure that the input shaft rotates smooth-
ly.

5A2 – 160IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
104. Remove any packing material and be careful
not to get oil on the contacting surfaces of the
transaxle housing or transaxle case.
105. Apply FIPG (formed in place gasket) to the
transaxle housing.
FIPG: Three bond 1281 or equivalent.
Seal bend width: 1.2 mm (0.047 in.)
106. Install the transaxle housing to the transaxle
case with the 16 bolts.
Tighten
Tighten the bolts to 29 NSm (22 lb–ft).
S Apply seal packing or equivalent to the 3 bolts
indicated by arrows.
107. Coat a new O–ring with ATF, install it to the
transaxle wire.
108. Install the transaxle wire the to the transaxle
case with the bolt.
Tighten
Tighten the bolts to 5.4 NSm (48 lb–in).