DAEWOO NUBIRA 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 27
DAEWOO V–121 BL4
5. Bolt the gearshift lever cover to the fixture KM–552.
6. Position the fixture KM–552 into the base
KM–113–2.
7. Remove the snap ring, the bushing, the spring, and
the intermediate lever.
8. Remove the shift finger lever pin.
9. Remove the gearshift rod and the shift finger lever.

5B – 28IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
10. Remove the bolt and the speedometer–driven gear
from the transaxle housing.
11. Remove the transaxle cover bolts.
12. Remove the transaxle cover.
13. Shift the transaxle into second gear.
14. Remove the bearing plate bolts.

FIVE–SPEED MANUAL TRANSAXLE 5B – 29
DAEWOO V–121 BL4
15. Remove the bearing plate from the case with the
shafts attached.
16. Shift the transaxle into reverse (R).
17. Bolt the bearing plate to the fixture KM–552 and
install the fixture KM–552 into the base KM–113–2.
18. Remove the bolts and the fifth–gear fork from the
bearing plate.
19. Remove the mainshaft–driven fifth–speed assembly
snap ring.

5B – 30IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
20. Remove the fifth driven gear synchronizer sleeve
and the synchronizer gear using the bearing puller
J–22888–20–A with the puller legs J–22888–35.
21. Remove the mainshaft–driven fifth–gear assembly.
22. Remove the brass synchronizer ring.
23. Remove the needle bearing, the retaining ring, and
the thrust washers.

FIVE–SPEED MANUAL TRANSAXLE 5B – 31
DAEWOO V–121 BL4
24. Remove the input drive fifth–gear snap ring.
25. Remove the input drive fifth gear using the fifth–
gear puller KM–553–A.
26. Remove the bolts and the fifth–gearshift connector
from the bearing plate using the pawl.
27. Remove the four shift–rod plugs using the shift rod
remover J–42469 and the slide hammer J–6125–B.

5B – 32IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
28. Remove the spring and the rod lock pin from the
small plug hole.
29. Remove the pin from the reverse gearshift rod/fork
assembly.
30. Remove the reverse gearshift rod/fork assembly
from the bearing plate.
31. Remove the bolts from the support bracket.

FIVE–SPEED MANUAL TRANSAXLE 5B – 33
DAEWOO V–121 BL4
32. Remove the first–second gearshift fork holding pin.
33. Drive the first–second gearshift rod out until it is just
free of the bearing plate.
34. Remove the support bracket from the bearing plate.
35. Remove the third–fourth gearshift fork holding pin
and the third–fourth gearshift rod.

5B – 34IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
36. Remove the fifth gearshift lever from the bearing
plate.
37. Remove the first–second gearshift rod.
38. Compress the snap ring holding the mainshaft and
secure it with the snap ring retainer J–36633.
39. Hold the snap ring open at the base of the input
shaft using the snap ring pliers.
40. Remove the mainshaft assembly and the input
shaft assembly from the bearing plate.

FIVE–SPEED MANUAL TRANSAXLE 5B – 35
DAEWOO V–121 BL4
INPUT SHAFT AND CLUSTER GEAR
Tools Required
J–22912–01 Universal Bearing Puller
Disassembly Procedure
1. Remove the detent screw at the end of the input
driveshaft.
2. Remove the snap ring at the base of the gear clus-
ter.
3. Press the input driveshaft from the input shaft clus-
ter gear using the universal bearing puller
J–22912–01.
4. Remove the cluster shaft bearing from the input
shaft gear cluster using universal bearing puller
J–22912–01.

5B – 36IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
Assembly Procedure
1. Press the cluster shaft bearing onto the input shaft
gear cluster.
2. Press the input driveshaft into the input shaft gear
cluster assembly.
3. Install the snap ring at the base of the gear cluster.
4. Install the detent screw at the end of the input dri-
veshaft.
Tighten
Tighten the input driveshaft detent screw to 15 NSm
(11 lb–ft).