DAEWOO NUBIRA 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 191
DAEWOO V–121 BL4
16. Install the forward and reverse clutch and thrust
needle roller bearing on the transaxle rear cover.
17. Using a dial indicator and measuring terminal
DW240–120, measure the forward clutch pack
clearance while applying and releasing 392 kpa (57
psi) of compressed air.
S The forward and reverse clutch will come out as
you apply the compressed air. Therefore, while
the checking is being done, press on the input
shaft of the forward and reverse clutch using
stamping machine or alike so that the pressure
is not applied on the forward and reverse clutch.
S Pack clearance: 1.1–1.5 mm (0.043
0.059 in.)
If the pack clearance is less than the limit of
pack clearance, parts may have been as-
sembled incorrectly, so check and reassemble
again.
If the pack clearance is non–standard, select
another flange.
There are 4 flanges in different thickness.
S Flange Thickness: mm (in.)
No
ThicknessNoThickness
13.0 (0.118)33.4 (0.134)
23.2 (0.126)43.6 (0.142)

5A2 – 192IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
COUNTER DRIVEN GEAR
1. Outer Tapered Roller Bearing Race
2. Tapered Roller Bearing
3. Counter Drive Pinion4. Counter Driven Gear
5. Tapered Roller Bearing
6. Outer Tapered Roller Bearing Race

AISIN AUTOMATIC TRANSAXLE 5A2 – 193
DAEWOO V–121 BL4
Tools Required
DW240–160 Transaxle Case Outer Tapered Roller Bear-
ing Race Adapter
DW240–170 Adapter Handle
Disassembly Procedure
1. Using a suitable puller, remove the tapered roller
bearing from the transaxle case side.
2. Using a press, remove the counter driven gear.
3. Using a suitable puller, remove the tapered roller
bearing.
4. Using a suitable puller, remove the outer tapered
roller bearing race and shim from the transaxle
case.
5. Using a suitable puller, remove the outer tapered
roller bearing race from the transaxle housing.
Assembly Procedure
1. 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.

5A2 – 194IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
2. Install the shim to the transaxle case.
S First install a shim of the same thickness as be-
fore.
3. 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.
4. Using a press, install the counter driven gear.
5. Using a press, install a new tapered roller bearing
of the transaxle case side.
6. Using a press, install a new tapered roller bearing
of .the transaxle housing side.

AISIN AUTOMATIC TRANSAXLE 5A2 – 195
DAEWOO V–121 BL4
VALVE BODY
1. Manual Valve
2. Upper Valve Body
3. Valve Body Plate
4. No1. Solenoid Valve
5. O–Ring
6. No2. Solenoid Valve7. O–Ring
8. Pressure Control Solenoid Valve
9. Lower Valve Body
10. Timing Solenoid Valve
11. O–Ring
12. Lock–up Solenoid Valve

5A2 – 196IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
1. Cover
2. Gasket
3. Cover Plate
4. Gasket
5. Pressure Relief Valve Spring Seat6. Spring
7. Ball
8. Check Ball
9. Spring
10. Check Valve

AISIN AUTOMATIC TRANSAXLE 5A2 – 197
DAEWOO V–121 BL4
Disassembly Procedure
1. Write down the relative position of the primary regu-
lator valve sleeve, plug and pin.
Notice : Because the line pressure is changed by the posi-
tion of the pin and groove in the sleeve end, be sure to
check the position.
2. Remove the manual valve.
3. Remove the 5 bolts and 5 shift solenoid valves.
4. Remove the 15 bolts.
5. Remove the cover, 2 gaskets and plate.

5A2 – 198IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
6. Remove the spring, check valve and check ball.
7. Remove the bolt, spring seat, spring and ball.
8. Turn over the valve body.
9. Remove the 2 bolts from the valve body.
10. Remove the upper valve body from the lower valve
body with plate.
11. Remove the valve body plate from the lower valve
body.
Notice : Be careful that the check balls do not fall out.

AISIN AUTOMATIC TRANSAXLE 5A2 – 199
DAEWOO V–121 BL4
Assembly Procedure
1. Install the valve body plate to the lower valve body.
2. Install the upper valve body to the lower valve body
with plate.
3. Install the 2 bolts to the valve body.
Tighten
Tighten the bolts to 11 NSm (97 lb–in).
Bolt A: 49 mm (1.93 in.)
Bolt B: 36 mm (1.42 in.)
4. Turn the valve body.
5. Install the check valve, spring and check ball.
6. Install the ball, spring, spring seat and bolt.
Tighten
Tighten the bolts to 6.5 NSm (57 lb–in).

5A2 – 200IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
7. Install the 2 gaskets, plate and lower valve body
cover.
8. First, tighten the bolts indicated by arrows tempo-
rarily and then tighten the other bolts temporarily.
9. Tighten all the bolts completely.
Tighten
Tighten the bolts to 11 NSm (97 lb–in).
S Bolt length:
Bolt A: 49 mm (1.93 in.)
Bolt B: 20 mm (0.79 in.)
Bolt C: 60 mm (2.36 in.)
10. Install the 5 shift solenoid valves with the 6 bolts.
Tighten
Tighten the bolts to 11 NSm (97 lb–in).
S Bolt length:
Bolt A: 49 mm (1.93 in.)
Bolt B: 20 mm (0.79 in.)
11. Install the manual valve.
12. Make sure that the primary regulator valve is posi-
tioned in the same place where it was removed.