DAEWOO LACETTI 2004 Service Repair Manual

5A1 – 212IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
UNIT REPAIR
TORQUE CONVERTER
Disassembly and Assembly Procedure
1. Remove the transaxle assembly. Refer to ”Trans-
axle Assembly” in this section.
2. Remove the torque converter assembly.
3. Installation should follow the removal procedure in
the reverse order.
TRANSAXLE HOLDING FIXTURE
ASSEMBLY
Tools Required
DW260–020 Transaxle Support Fixture
CAUTION : To reduce the possibility of personal inju-
ry or transaxle damage, make sure, when doing the
next step, that all of the bolts for the support fixture
are installed as shown, and that the bolts are tight-
ened to 11 NSm (98 lb–in).
Disassembly and Assembly Procedure
1. Install the transaxle support fixture DW260–020
onto the transaxle.
2. Torque the support fixture bolts to 11 NSm (98 lb–
in).
3. Position the transaxle with the rear cover facing up.
VALVE BODY
Disassembly and Assembly Procedure
1. Remove the oil pan bolts and oil pan.
2. Remove the oil pan gasket.
Installation Notice
Tighten the oil pan bolts to 6 NSm (53 lb–in).

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 213
DAEWOO V–121 BL4
3. Remove valve body fixing bolts and transaxle input
speed sensor bolt on the valve body.
4. Remove the holder for the transaxle input speed
sensor.
Installation Notice
Tighten the bolts to 8 NSm (71 lb–in).
5. Tilt the valve body.
6. Remove the fastening screw for the output speed
sensor under the valve body assembly.
7. Lever the cable out of the retaining clip and pull out
the output speed sensor.
8. Installation should follow the removal procedure in
the reverse order.
Installation Notice
Tighten the screw to 6 NSm (53 lb–in).
REAR COVER
Disassembly and Assembly Procedure
1. Removal the valve body assembly. Refer to ”Valve
Body Removal” in this section.
2. Pull out sealing sleeve (brake C) with a kind of nail.
3. Turn transaxle by 90°.
4. Remove the rear cover bolts.
5. Hit the rear cover rightly.
6. Remove the cover.
7. Installation should follow the removal procedure in
the reverse order.
Installation Notice
Tighten the rear cover bolts to 23 NSm (17 lb–ft).

5A1 – 214IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
CLUTCH B/E
Tools Required
DW260–140 Clutch B Stop Ring Remover/Installer
DW260–150 Clutch B Stop Ring Remover/Installer
Disassembly and Assembly Procedure
1. Remove the rear cover. Refer to ”Rear Cover Re-
moval” in this section.
2. Remove the two sealing rings(clutch B/E).
3. Take out input shaft with clutch B/E.
4. Remove needle bearing and thrust washer.
5. Remove shim.
6. Take out the retaining snap ring.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 215
DAEWOO V–121 BL4
7. Take out the piston B.
8. Remove disc set B.
9. Take out the piston rings.
Removal Notice
S Remove the rectangular–section ring for the in-
put shaft and the retaining ring.
10. Remove inner disc carrier E and needle roller thrust
bearing.

5A1 – 216IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
11. Take out the snap ring.
12. Remove disc set E.
13. Press down cup spring(clutch E) with cup spring
press fixture.
14. Remove the split stop ring.
15. Remove the oil dam and cup spring.
16. Pull the o–ring off the oil dam.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 217
DAEWOO V–121 BL4
17. Press down cup spring(clutch B)with cup spring
press fixture.
18. Remove the split stop ring.
19. Remove the cup spring.
20. Installation should follow the removal procedure in
the reverse order.
Adjustment Notice
Before assembling clutch B/E, setting discs(clutch B/E)
have to measured by below measurement procedure.
CLUTCH B/E MEASUREMENT
PROCEDURE
Tools Required
DW260–090 Clutch B/E(snap ring play, installation space)
Measuring Fixture
Determine Snap Ring Play
1. Put the dial gauge sensor on the clutch B adjusting
ring.
2. Feed compressed air to clutch B via control valves.
3. Set dial gauge to zero.
4. Pressurize clutch E via the control valve and read
measurement value.
5. Repeat measurement twice with disc set turned by
120°.
6. Average measurement values M1, M2, M3.(mea-
surement value is S)
S CALCULATION
S = (M1+M2+M3)/3
S EXAMPLE
– M1 = 0.27mm, M2 = 0.23mm, M3 = 0.25mm
– S = 0.25mm

5A1 – 218IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Tools Required
DW260–090 Clutch B/E (snap ring play, installation
space) Measuring Fixture
Measuring Installation Space, Clutch B
(EB)
1. Put the dial gauge’s sensor on the clutch B adjust-
ing ring.
2. Feed compressed air to clutch E via control valves.
3. Set dial gauge to zero.
4. Lift measurement ring B by hand until it touches the
cup and read the measurement value.
5. Repeat measurement twice with the set turned by
120°.
6. Average measurement values M4, M5, M6. (mea-
surement value is MB)
S The minimum installation space EB is equal to
the height of the ring RB (specification value ;
11.99mm) plus measurement value MB
S CALCULATION
MB = (M4+M5+M6)/3
EB = RB + MB
S EXAMPLE
M4 = 2.36mm
M5 = 2.40mm
M6 = 2.38mm
So,MB = (2.36+2.40+2.38)/3 = 2.38mm
EB = 11.99+2.38 =14.37mm
Tools Required
DW260–090 Clutch B/E(snap ring play, installation space)
Measuring Fixture
Measuring Installation Space, Clutch E(EE)
1. Put the dial gauge’s sensor on the clutch E adjust-
ing ring.
2. Set dial gauge to zero.
3. Feed compressed air to clutch E via control valves.
4. Read off the measured value.
5. Repeat measurement twice with the set turned by
120°.
6. Average measurement values M7, M8, M9. (mea-
surement value is ME)
S The minimum installation space BE is equals
ring height RE (specification value : 20.98mm)
plus ME – minus snap ring play S.
S CALCULATION
ME = (M7+M8+M9)/3
EE = RE + ME–S
S EXAMPLE
M7 = 2.6mm
M8 = 2.55mm
M9 = 2.54mm
So,ME = (2.6+2.55+2.54)/3 = 2.56mm
EE = 20.98+2.56–0.25 = 23.29mm

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 219
DAEWOO V–121 BL4
Tools Required
DW260–100 Brake B/E Disc Thickness Measuring Fixture
Determining Adjusting Disc B(PB)
1. Using disc thickness gauge, determine thickness
ME for the disc set for clutch B(without adjusting
disc, which located in second highest plate).
2. Calculate the test dimension PB(PB = EB – MB)
EB = installation space
MB = disc set thickness
S EXAMPLE
EB = 14.37mm
MB = 11.3mm
PB = 3.07mm
3. Find the disc set’s thickness. Refer to the below
table.
PB
Disc set’s Thickness
2.83~3.39mm1.8mm
3.40~3.68mm2.1mm
3.69~4.08mm2.5mm
4.09~4.54mm3.0mm
PB is 3.08mm so, the disc set’s thickness is
1.8mm.
4. Replace clutch B’s setting disc. (1.8mm)
Tools Required
DW 260–100 Brake B/E Disc Thickness Measuring Fix-
ture
Determining Adjusting Disc E(PE)
1. Using disc thickness gauge, determine thickness
MB for the disc set for clutch E(without adjusting
disc, which located in the lowest plate).
2. Calculate the test dimension PE(PE = EE – ME)
EE = installation space
MB = disc set thickness
S EXAMPLE
EE = 23.29mm
ME = 16.70mm
PE = 6.59mm
3. Find the disc set’s thickness. Refer to the below
table.
PE
Disc set’s Thickness
5.41~6.00mm3.9mm
6.01~6.48mm4.4mm
6.49~6.98mm5.0mm
PB is 3.08mm so, the disc set’s thickness is
5.0mm.
4. Replace clutch B’s setting disc. (5.0mm)

5A1 – 220IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
PLANETARY GEAR SET
Disassembly and Assembly Procedure
1. Remove the clutch B/E. Refer to ”Clutch B/E” in
this section.
2. Remove the rear sun gear.
3. Remove the planetary gear set.
4. Remove snap ring from front ring gear.
5. Take out rear planetary gear set.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 221
DAEWOO V–121 BL4
6. Remove the axial needle bearing.
7. Take out front gear set with rear ring gear, front sun
gear and oil trays.
8. Take oil trays and front sun gear off the planetary
gear set.
9. Installation should follow the removal procedure in
the reverse order.
BRAKE C/D
Tools Required
DW260–160 Brake C/D Snap Ring Remover/Installer
Disassembly and Assembly Procedure
1. Take snap ring out of transaxle housing.