DAEWOO LACETTI 2004 Service Repair Manual

SECTION : 5A2
AISIN AUTOMATIC TRANSAXLE
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS5A2–3 . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5A2–3. . . . . . . . . . . . . . . . . . . .
Transaxle Gear Ratio 5A2–3. . . . . . . . . . . . . . . . . . . . . .
Fluid Capacity 5A2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Specification 5A2–3. . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5A2–4. . . . . . . . . .
SPECIAL TOOLS5A2–5 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5A2–5. . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC DIAGRAMS5A2–8 . . . . . . . . . . . . . . . . . . .
Transmission Control Module (1 of 4) 5A2–8. . . . . . . .
Transmission Control Module (2 of 4) 5A2–9. . . . . . . .
Transmission Control Module (3 of 4) 5A2–10. . . . . . .
Transmission Control Module (4 of 4) 5A2–11. . . . . . .
Shift Mode Diagram 5A2–12. . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR5A2–17 . . . . . . . . . . . . . . . . . .
Shift Select Control 5A2–17. . . . . . . . . . . . . . . . . . . . . .
Automatic Transaxle Components 5A2–18. . . . . . . . .
Bearing and Races Installation Position
Direction 5A2–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5A2–25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connector View 5A2–25. . . . . . . . . . . . . . . . .
Wiring Harness and Connector Inspection 5A2–27. . .
Road Test 5A2–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Check 5A2–28. . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Inspection 5A2–30. . . . . . . . . . . . . . . . . . . . . . . . . .
On–Vehicle Repair (Matrix Chart) 5A2–34. . . . . . . . . .
DIAGNOSIS TROUBLE CODE DIAGNOSIS5A2–36 .
Diagnosis Trouble Code Chart 5A2–36. . . . . . . . . . . . .
DTC P0562 System Voltage Low 5A2–37. . . . . . . . . .
DTC P0563 System Voltage High 5A2–40. . . . . . . . . .
DTC P0601 Internal Control Module Memory
Checksum Error 5A2–43. . . . . . . . . . . . . . . . . . . . . . .
DTC P0604 Internal Transmission Control Module
(TCM) Random Access Memory (RAM)
Error 5A2–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0705 Transmission Range (TR) Switch
Circuit Malfunction 5A2–47. . . . . . . . . . . . . . . . . . . . .
DTC P0712 Transmission Fluid Temperature
(TFT) Sensor Circuit Low Input 5A2–50. . . . . . . . . .
DTC P0713 Transmission Fluid Temperature
(TFT) Sensor Circuit High Input 5A2–53. . . . . . . . . .
DTC P0717 Input Shaft Speed (ISS) Sensor
Circuit No Signal 5A2–56. . . . . . . . . . . . . . . . . . . . . . .
DTC P0722 Ouput Shaft Speed (OSS) Sensor
Circuit No Signal 5A2–59. . . . . . . . . . . . . . . . . . . . . . .
DTC P0727 Engine Speed Input Circuit No
Signal 5A2–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0741 Torque Converter Clutch (TCC)
Circuit Stuck Off 5A2–65. . . . . . . . . . . . . . . . . . . . . . .
DTC P0742 Torque Converter Clutch (TCC)
Circuit Stuck On 5A2–67. . . . . . . . . . . . . . . . . . . . . . .
DTC P0743 Torque Converter Clutch (TCC)
Electrical 5A2–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0748 Pressure Control Solenoid (PCS)
Electrical 5A2–72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0751 Shift Solenoid 1 (SS1) Stuck Off 5A2–75
DTC P0753 Shift Solenoid 1 (SS1) Electrical 5A2–77
DTC P0756 Shift Solenoid 2 (SS2) Stuck Off 5A2–80
DTC P0758 Shift Solenoid 2 (SS2) Electrical 5A2–82
DTC P0785 Timing Solenoid (ST) Electrical 5A2–85.
DTC P1781 Engine Torque Signal Error 5A2–88. . . . .
DTC P1791 Throttle Position Signal Error 5A2–91. . .
DTC P1792 Engine Coolant Temperature (ECT)
Signal Error 5A2–93. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC U2105 Can Error 5A2–95. . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR5A2–97 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 5A2–97. . . . . . . . . . . . . . . . . . .
Transaxle Fluid Level Checking Procedure 5A2–97. .
Fluid Drain Procedure 5A2–97. . . . . . . . . . . . . . . . . . . .
Locating Fluid Leaks 5A2–98. . . . . . . . . . . . . . . . . . . . .
Case Porosity Repair 5A2–98. . . . . . . . . . . . . . . . . . . . .
Fluid Cooler Flushing 5A2–99. . . . . . . . . . . . . . . . . . . . .
Control Cable Adjustment 5A2–99. . . . . . . . . . . . . . . . .

5A2 – 2IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Shift Control Lever Assembly 5A2–100. . . . . . . . . . . . .
Transmission Range (TR) Switch 5A2–101. . . . . . . . .
Shift Control Cable 5A2–104. . . . . . . . . . . . . . . . . . . . . .
Shift Select Cover 5A2–105. . . . . . . . . . . . . . . . . . . . . .
Input Shaft Speed (ISS) Sensor 5A2–106. . . . . . . . . .
Output Shaft Speed (OSS) Sensor 5A2–107. . . . . . . .
Transmission Control Module (TCM) 5A2–108. . . . . .
Fluid Cooler Inlet Pipes and Hoses 5A2–109. . . . . . . .
Fluid Cooler Outlet Pipes and Hoses 5A2–110. . . . . .
Transaxle Assembly 5A2–111. . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 5A2–117. . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Disassembly 5A2–117. . . . . . . . . . .
Major Component Assembly 5A2–137. . . . . . . . . . . . .
Oil Pump 5A2–167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Clutch 5A2–171. . . . . . . . . . . . . . . . . . . . . . . . . . .
Planetary Ring Gear 5A2–178. . . . . . . . . . . . . . . . . . . .
One–Way Clutch 5A2–180. . . . . . . . . . . . . . . . . . . . . . .
Forward and Reverse Clutch 5A2–183. . . . . . . . . . . . .
Counter Driven Gear 5A2–192. . . . . . . . . . . . . . . . . . . .
Valve Body 5A2–195. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Case 5A2–208. . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION5A2–218 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transaxle Description 5A2–218. . . . . . . . . . . . . . . . . . .
Electronical Components 5A2–218. . . . . . . . . . . . . . . .
Hydraulic Control System 5A2–221. . . . . . . . . . . . . . . .
Automatic Transaxle System 5A2–222. . . . . . . . . . . . .

AISIN AUTOMATIC TRANSAXLE 5A2 – 3
DAEWOO V–121 BL4
SPECIFICATIONS
GENERAL SPECIFICATIONS
Definition
1.6 DOHC
Transaxle Fluid TypeISU DEXRON III or ESSO JWS 3309
Transaxle Fluid Capacity5.77L (6.1 qts)
TRANSAXLE GEAR RATIO
GearRatio
1.6 DOHC
First2.875
Second1.568
Third1.000
Fourth0.697
Reverse2.300
Counter1.020
Differential3.750
FLUID CAPACITY
Capacity
1.6 DOHC
Transaxle Fluid (dry fill)5.77L (6.1 qts)
Transaxle Fluid (drain and refill)2.1L (2.2 qts)
Notice : Fluid capacity (drain and refill) could be changed according to the some condition, therefore be sure to check
the fluid using the oil stick guage.
LINE PRESSURE SPECIFICATION
ApplicationIdlingStall
At ”D” range3.9–4.2 kg/cm2 (55–60 psi)11.3–12.5 kg/cm2 (161–178 psi)
At ”R” range6.0–6.9 kg/cm2 (85–98 psi)16.2–18.6 kg/cm2 (230–265 psi)

5A2 – 4IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Drain Plug1713–
Control Cable Adjusting Nut8–71
Shift Control Lever Assembly Mounting Bolts8–71
Manual Valve Lever Shaft Nut12–106
Transmission Range (TR) Switch Bolts5.4–48
Input Speed Sensor Retaining Bolt5.4–48
Output Speed Sensor Retaining Bolt7.4–65
TCM Retaining Bolts5–44
Fluid Cooler Inlet Pipe Fitting Nut3526–
Fluid Cooler Inlet Pipe Bolt9–80
Inlet Pipe Union Bolt3526–
Fluid Cooler Rear Outlet Pipe Fitting Nut3526–
Fluid Cooler Rear Outlet Pipe Clip Bolt9–80
Front Outlet Pipe Union Bolt3526–
Lower Transaxle–to–Engine Retaining Bolts (a)7354–
Lower Transaxle–to–Engine Retaining Bolts (b)3123–
Lower Transaxle–to–Engine Retaining Bolts (c)2115–
Upper Transaxle–to–Engine Mounting Bolts7354–
Upper Transaxle Mounting Bracket Bolts6044–
Rear Mounting Bracket Bolts6044–
Damping Block Connection Nut and Bolt8059–
Torque Converter Bolts4543–
Screw Plugs7.4–65
Transaxle Apply Clamp Bolt5.4–48
Oil Reservoir Lock Plate Bolts5.4–48
Transaxle Case Plate Bolt9.8–87
Transaxle Housing Bolts2922–
Manual Detent Spring Bolt9.8–87
Parking Lock Pawl Bracket Bolts7.4–65
Planetary Ring Gear Nut (Standard)9.8–87
Planetary Ring Gear Nut (Maximum)2922–
Transaxle Rear Cover Bolts2518–
Oil Pump Bolts2518–
Valve Body Bolts11–97
Oil Strainer Bolts9.8–87
Oil Pan Bolts7–62
Unions2518–
Stator Shaft Bolts2518–
Shift Solenoid Valve Bolts11–97
Differential Case–to–Differential Ring Gear Bolt10275–

AISIN AUTOMATIC TRANSAXLE 5A2 – 5
DAEWOO V–121 BL4
SPECIAL TOOLS
SPECIAL TOOLS TABLE
DW260–021–02
Automatic
Transaxle
Overhaul
Fixture
DW240–020
Brake/Clutch
Spring Compressor
DW240–030
Forward Clutch
Adapter
DW240–040
Direct Clutch
Adapter
DW240–050
Overdrive
Brake Adapter
DW240–060–01
Brake Spring
Compressor
Bolt/Nut
DW240–060–02
Brake Spring
Compressor
Plate
DW240–070
1st/Reverse
Brake Adapter

5A2 – 6IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DW240–080
2nd Brake Adapter
DW240–090
Planetary Ring
Gear Remover
DW240–100
Counter Drive
Gear Installation
Adapter
DW260–041
Planetary Ring
Gear Nut
Removal/Installation
Socket (52mm)
DW260–031–01
Tranaxle Housing
Oil Seal Installer
DW260–031–02
Tranaxle Case
Oil Seal Installer
DW240–120
Measuring Terminal
DW240–130
Differential Preload
Adapter
DW260–013
Transaxle Support
Fixture
DW240–140
Transaxle Housing
Side Bearing
Outer Race
Adapter

AISIN AUTOMATIC TRANSAXLE 5A2 – 7
DAEWOO V–121 BL4
DW240–150
Transaxle Case
Side Bearing
Outer Race
Adapter
DW240–160
Transaxle Case
Outer Tapered
Roller Bearing
Race Adapter
DW240–170
Adapter Handle

5A2 – 8IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
SCHEMATIC DIAGRAMS
TRANSMISSION CONTROL MODULE (1 OF 4)

AISIN AUTOMATIC TRANSAXLE 5A2 – 9
DAEWOO V–121 BL4
TRANSMISSION CONTROL MODULE (2 OF 4)

5A2 – 10IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
TRANSMISSION CONTROL MODULE (3 OF 4)