DAEWOO NUBIRA 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 17
DAEWOO V–121 BL4
GEARSHIFT LEVER
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
Removal Procedure
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
3. Disconnect the boot from the console cover.
4. Lift the console cover upward to expose the shift
control lever mechanism.
5. Rotate the gearshift lever stop clamp and remove it.
6. Remove the gearshift lever from the gearshift lever
shaft.
Installation Procedure
1. Install the gearshift lever into the gearshift lever
shaft.
2. Install the gearshift lever stop clamp.
3. Rotate the gearshift lever stop clamp to secure it.
4. Lower the boot and connect it to the console cover.
5. Connect the negative battery cable.

5B – 18IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
GEARSHIFT LEVER HOUSING
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the rod clamp. Refer to ”Shift Linkage Ad-
justment” in this section.
3. Remove the console.
4. Remove the gearshift lever housing bolts and the
gearshift lever housing.
Installation Procedure
1. Install the gearshift lever housing and the gearshift
lever housing bolts.
Tighten
Tighten the gearshift housing bolts to 7 NSm ( 62 lb–
in).
2. Adjust the shift linkage.
3. Install the console.
4. Connect the negative battery cable.
SPEEDOMETER DRIVEN GEAR
Removal Procedure
1. Disconnect the speedometer speed sensor electri-
cal connector.
2. Remove the speedometer housing retaining bolt.
3. Remove the speedometer–driven gear and the
speedometer housing.

FIVE–SPEED MANUAL TRANSAXLE 5B – 19
DAEWOO V–121 BL4
Installation Procedure
1. Coat the O–ring with petroleum jelly.
2. Install the speedometer–driven gear and the
speedometer housing.
3. Install the speedometer housing retaining bolt.
Tighten
Tighten the speedometer housing retaining bolt to 4
NSm (35 lb–in).
4. Connect the speedometer speed sensor electrical
connector.
SHIFT LINKAGE ASSEMBLY
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the rod clamp. Refer to ”Shift Linkage Ad-
justment” in this section.
3. Remove the clip and the bolt from universal joint.
4. Separate the universal joint from the transaxle.
5. Remove the fixing shaft pin and separate the link-
age connection part from the transaxle rear mount-
ing bracket.
6. Remove the shift linkage assembly.

5B – 20IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Install the shift linkage assembly.
2. Install the fixing shaft pin and connect the linkage
connection part to the transaxle rear mounting
bracket.
3. Install the universal joint to the transaxle.
4. Install the clip and the bolt from universal joint.
5. Install the rod clamp. Refer to ”Shift Linkage Adjust-
ment” in this section.
6. Adjust the shift linkage. Refer to ”Shift Linkage Ad-
justment” in this section.
7. Connect the negative battery cable.
DRIVE AXLE SEAL
Tools Required
KM–519 Ring Installer
Removal Procedure
Notice : Do not damage the bearing adjusting ring with the
pry bar.
1. Remove the drive axle from the transaxle. Refer to
Section 3B, Manual Transaxle Drive Axle.
2. Remove the drive axle seal by lifting the outer lip of
the seal with a pry bar.
Installation Procedure
1. Install the new drive axle seal using the ring install-
er KM–519 and a hammer.
2. Coat the seal lip with the transaxle fluid.
3. Install the drive. Refer to Section 3B, Manual Trans-
axle Drive Axle.

FIVE–SPEED MANUAL TRANSAXLE 5B – 21
DAEWOO V–121 BL4
TRANSAXLE ASSEMBLY
Tools Required
J–28467–B Engine Support Fixture
Removal Procedure
1. Install the engine support fixture J–28467–B.
2. Remove the battery and battery tray. Refer to Sec-
tion 1E, ENGINE ELETRICAL.
3. Remove the shift linkage assembly. Refer to ”Shift
Linkage Adjustment” in this section.
4. Remove the drive axle shaft. Refer to Section 3B,
Manual Transaxle Drive Axle.
5. Disconnect the backup lamp switch electrical con-
nector.
6. Disconnect the speedometer speed sensor electri-
cal connector.
7. Remove the pin and the clutch release cylinder
pipe.
8. Remove the damping block connection nut and
bolt.
9. Remove the three rear mounting bracket bolts.
10. Remove the rear mounting bracket from the trans-
axle.

5B – 22IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
11. Remove the two rear damping block retaining bolts.
12. Remove the rear damping block from the front
cross member.
13. Remove the two cage retaining bolts.
14. Remove the three transaxle upper mounting brack-
et bolts.
15. Remove the upper mounting bracket and cage.
16. Remove the three transaxle upper retaining bolts.
17. Support the transaxle with a transaxle support jack.

FIVE–SPEED MANUAL TRANSAXLE 5B – 23
DAEWOO V–121 BL4
18. Remove the seven transaxle lower retaining bolts.
19. Remove the transaxle.
Notice : Rest the transaxle only in an upright position.
20. Slide the transaxle sideways away from the engine
block.
21. Lower the transaxle.
Installation Procedure
1. Support the transaxle with a transaxle support jack.
2. Install the transaxle by inserting the transaxle input
shaft into the clutch disc and sliding the transaxle
sideways into the engine block.
3. Install the seven transaxle lower retaining bolts.
Tighten
Tighten the transaxle lower retaining bolts(a) to 73
NSm ( 54 lb–ft ).
Tighten the transaxle lower retaining bolt(b) to 31 NSm
( 23 lb–ft ).
Tighten the transaxle lower retaining bolts(c) to 21
NSm ( 15 lb–ft ).

5B – 24IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
4. Install the three transaxle upper retaining bolts.
Tighten
Tighten the transaxle upper retaining bolts to 73 NSm
(54 lb–ft ).
5. Install the cage retaining bolt and cage.
6. Install the three transaxle upper mounting bracket
bolts and bracket.
Tighten
Tighten the transaxle upper mounting bracket bolts to
48 NSm (35 lb–ft ).
7. Install the two rear damping block retaining bolts.
Tighten
Tighten the rear damping block retaining bolts to 68
NSm (50 lb–ft ).
8. Install the rear damping block from the front cross
member.
9. Install the three rear mounting bracket bolts and the
bracket.
Tighten
Tighten the rear mounting bracket bolts to 90 NSm (66
lb–ft ).
10. Install the damping block connection nut and bolt.
Tighten
Tighten the damping block connection nut and bolt to
68 NSm (50 lb–ft ).

FIVE–SPEED MANUAL TRANSAXLE 5B – 25
DAEWOO V–121 BL4
11. Connect the clutch release cylinder pipe.
12. Connect the speedometer speed sensor electrical
connector.
13. Connect the backup lamp switch electrical connec-
tor.
14. Remove the engine support fixture J–28467–B.
15. Install the drive axle shaft. Refer to Section 3B,
Manual Transaxle Drive Axle.
16. Install the shift linkage assembly. Refer to ”Shift
Linkage Assembly” in this section.
17. Install the battery and battery tray. Refer to Section
1E, ENGINE ELETRICAL.
18. Inspect the fluid level. Refer to ”Checking Fluid Lev-
el” in this section.

5B – 26IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
UNIT REPAIR
MAJOR COMPONENT DISASSEMBLY
Tools Required
J–6125–B Slide Hammer
J–22888–20–A BearingPuller with J–22888–35 Puller
Legs
KM–553–A Fifth Gear Puller
J–36633 Snap Ring Retainer
KM–113–2 Base
J–42469 Shift Rod Remover
KM–552 Fixture
Disassembly Procedure
1. Remove the transaxle from the vehicle. Refer to
”Transaxle Assembly” in this section.
2. Remove the filler plug at the cover.
3. Remove the bolts from the gearshift lever cover.
4. Remove the gearshift lever cover.