DAEWOO LACETTI 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 181
DAEWOO V–121 BL4
Disassembly Procedure
1. Install the one–way clutch and thrust washer to the
rear planetary sun gear.
2. Hold the rear planetary sun gear and turn the one–
way clutch. The one–way clutch should turn freely
clockwise and should lock counterclockwise.
3. Using a screwdriver, remove the snap ring from the
2nd brake hub.
4. Remove the one–way clutch from the 2nd brake
hub.
5. Using a small screwdriver, remove the retainer from
the 2nd brake hub.

5A2 – 182IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Assembly Procedure
1. Install the retainer to the 2nd brake hub.
2. Install the one–way clutch.
3. Using a screwdriver, install the snap ring.
4. Install the one–way clutch and thrust washer to the
rear planetary sun gear.
5. Hold the rear planetary sun gear and turn the one–
way clutch. The one–way clutch should turn freely
clockwise and should lock counterclockwise.

AISIN AUTOMATIC TRANSAXLE 5A2 – 183
DAEWOO V–121 BL4
FORWARD AND REVERSE CLUTCH
1. Seal Ring
2. Flange
3. Disc
4. Plate
5. Flange
6. Snap Ring
7. Flange
8. Disc
9. Plate10. Snap Ring
11. Clutch Balancer
12. Forward Clutch Retrun Spring
13. Forward Clutch Piston
14. O–Ring
15. Forward Clutch Drum
16. O–Ring
17. Intermediate Shaft Sub–assembly

5A2 – 184IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Tools Required
DW240–020 Brake/Clutch Spring Compressor
DW240–030 Forward Clutch Adapter
DW240–120 Measuring Terminal
Disassembly Procedure
WARNING : USE CAUTION WHEN CHECKING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
1. Install the forward and reverse clutch and thrust
needle roller bearing on the transaxle rear cover.
2. Using a dial indicator, measure the reverse clutch
pack clearance while applying and releasing 392
kPa (57 psi) of compressed air.
S Pack clearance: 0.40
1.00 mm (0.0157

0.0394 in.)
S If the stroke is non–standard, inspect the discs,
plates and flange.
WARNING : USE CAUTION WHEN CHECKING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
3. Install the forward and reverse clutch and thrust
needle roller bearing on the transaxle rear cover.
4. 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 stroke is non–standard, inspect the discs,
plates and flange.
5. Using a screwdriver, remove the reverse clutch
snap ring.

AISIN AUTOMATIC TRANSAXLE 5A2 – 185
DAEWOO V–121 BL4
6. Remove the 2 flanges, 2 discs and plate from the
reverse clutch drum.
7. Using a screwdriver, remove the snap ring.
8. Remove the flange, 3 discs and 3 plates from the
forward clutch drum.
9. Using brake/clutch spring compressor DW240–020
and forward clutch adapter DW240–030, compress
the spring.
10. Using a snap ring expander, remove the snap ring.
Notice : Stop the press when the clutch balancer is low-
ered to the place 1–2 mm (0.039–0.078 in.) from the snap
ring groove, preventing the clutch balancer from being de-
formed.
Notice : Do not expand the snap ring excessively.

5A2 – 186IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
11. Remove the clutch balancer and forward clutch re-
turn spring.
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
12. Install the forward and reverse multiple disc clutch
on the transaxle rear cover.
13. Apply 392 kPa (57 psi) of compressed air to the
transaxle rear cover to remove the forward clutch
piston.
Notice : Blowing off the air may cause the piston’s jump–
out.When removing the piston, hold it with your hand using
a waste cloth.
Notice : Take care not to splash ATF when air–blowing.
S When the piston can not be removed as it is
slanted, either blow the air again with the pro-
truding side pushed or remove the piston using
a needle nose pliers with vinyl tape on the tip.
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
14. Apply 392 kPa (57 psi) of compressed air to the
transaxle rear cover to remove the forward clutch
drum.
Notice : Blowing off the air may cause the drum’s jump–
out. When removing the drum, hold it with your hand using
a waste cloth.
Notice : Take care not to splash ATF when air–blowing.
S When the drum can not be removed as it is
slanted, either blow the air again with the pro-
truding side pushed or remove the drum using a
needle nose pliers with vinyl tape on the tip.

AISIN AUTOMATIC TRANSAXLE 5A2 – 187
DAEWOO V–121 BL4
15. Using a small screwdriver, remove the O–ring from
the forward clutch drum.
16. Using a small screwdriver, remove the O–ring from
the intermediate shaft sub–assembly.
Inspection Procedure
1. Check to see if the sliding surface of the disc, plate
flange are worn or burnt. If necessary, replace
them.
S If the lining of the disc is peeling off or discol-
ored, or even if a part of the printed number is
defaced, replace all discs.
S Before assembling new discs, soak them in ATF
for at least 15 minutes.
2. Using vernier calipers, measure the free length of
the spring together with the spring seat.
S Standard free length: 24.04 mm (0.9465 in.)

5A2 – 188IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Assembly Procedure
1. Coat a new O–ring with ATF, and install it to the
intermediate shaft sub–assembly.
2. Coat a new O–ring with ATF, and install it to the
forward clutch drum.
3. Coat the forward clutch drum with ATF, install the
forward clutch drum.
Notice : Be careful not to damage the O–ring and lip seal
of forward clutch drum.
4. Coat the forward clutch piston with ATF, install the
forward clutch piston.
Notice : Be careful not to damage the lip seal of forward
clutch piston.

AISIN AUTOMATIC TRANSAXLE 5A2 – 189
DAEWOO V–121 BL4
5. Install the forward clutch return spring and clutch
balancer.
Notice : Be careful not to damage the lip seal of forward
clutch return spring.
6. Place brake/clutch spring compressor DW240–020
and forward clutch adapter DW240–030 on the
clutch balancer and compress the piston return
spring.
7. Using a snap ring expander, install the snap ring.
Notice : Stop the press when the clutch balancer is low-
ered to the place 1–2 mm (0.039–0.078 in.) from the snap
ring groove, preventing the clutch balancer from being de-
formed.
Notice : Do not expand the snap ring excessively.
8. Install the 3 plates, 3 discs and flange.
S Install in order: P
D
P
D
P
D – F
(P = Plate, D = Disc, F = Flange)
9. Using a screwdriver, install the snap ring.
10. Check that the end gap of the snap ring is not
aligned with one of the cutouts.

5A2 – 190IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
11. Install the plate, 2 discs and 2 flanges.
S Install in order: F
D
P
D – F
(P = Plate, D = Disc, F = Flange)
12. Using a screwdriver, install the snap ring.
13. Check that the end gap of the snap ring is not
aligned with one of the cutouts.
WARNING : USE CAUTION WHEN CHECKING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
14. Install the forward and reverse clutch and thrust
needle roller bearing on the transaxle rear cover.
15. Using a dial indicator, measure the reverse clutch
pack clearance while applying and releasing 392
kPa (57 psi) of compressed air.
S Pack clearance: 0.40
1.00 mm (0.0157

0.0394 in.) If the pack clearance is less than the
limit of pack clearance, parts may have been
assembled 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)