DAEWOO LACETTI 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 7
DAEWOO V–121 BL4
Checks Action
Check for a noise in the fourth gear (4) only.S Replace any chipped, scored, or worn fourth gear or
output gear.
S Replace any worn third–fourth gear synchronizer.
S Replace any worn fourth–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the fifth gear (5) only.S Replace any chipped, scored, or worn fifth gear or
output gear.
S Repair any worn fifth–gear synchronizer.
S Replace any worn fifth–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the reverse (R) gear only.S Replace any chipped, scored, or worn reverse idler
gear, idler–gear bushing, input gear, or output gear.
S Replace any worn first–second gear synchronizer.
S Replace any worn output gear.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
Check for a noise in all gears.S Add sufficient lubricant.
S Replace any worn bearings.
S Replace any chipped, scored, or worn input–gear
shaft or output–gear shaft.
Check for the transaxle slipping out of gear.S Adjust or replace the linkage, as needed.
S Adjust, repair, or replace any binding shift linkage.
S Tighten or replace the input–gear bearing retainer, as
needed.
S Repair or replace any worn or bent shift fork.
Check for a leak in the area of the clutch.S Repair the transaxle casing.
S Replace any damaged release bearing guide.
Check for a leak at the center of the transaxle.S Repair the transaxle casing.
S Repair the shift mechanism.
S Replace the damaged backup lamp switch.
Check for a leak at the differential.S Adjust or replace the bearing retainers.
S Tighten or replace the differential cover.
S Adjust or replace the drive axle shaft seals.

5B – 8IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
Checks Action
Check for a hard shift.S Replace any damaged release–bearing guide.
S Adjust, repair, or replace the shift mechanism.
S Adjust, repair, or replace the clutch–release system.
S Replace any chipped, scored, or worn fifth–gear syn-
chronizer.
S Replace any chipped, scored, or worn first–second
gear synchronizer.
S Replace any worn third–fourth gear synchronizer.
S Adjust, repair, or replace the shift lever and the rods.
Check for a clashing of gears.S Replace any damaged release–bearing guide.
S Adjust, repair, or replace the clutch–release system.
S Replace the chipped, scored, or worn input shaft/
gear–cluster gears.
S Replace any worn fifth–gear synchronizer.
S Replace any worn fifth–gear/bearing.
S Replace any worn first–gear/bearing.
S Replace any worn first–second gear synchronizer.
S Replace any worn second–gear/bearing.
S Replace any worn third–gear/bearing.
S Replace any worn third–fourth synchronizer.
S Replace any worn fourth–gear/bearing.
S Replace any worn reverse–idler gear.

FIVE–SPEED MANUAL TRANSAXLE 5B – 9
DAEWOO V–121 BL4
COMPONENT LOCATORS
GEARS AND CASE

5B – 10IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
1. Roller Bearing
2. Transaxle Main Shaft
3. Washer
4. Washer Retaining Ring
5. 4th Speed Gear
6. Needle Cage
7. Synchronizer Ring
8. Shift Sleeve
9. Synchronizer Key
10. 3rd & 4th Synchronizer Spring
11. Washer
12. Circlip
13. 3rd Speed Gear
14. Washer
15. Washer Retaining Ring
16. 2nd Speed Gear
17. Needle Cage
18. Inside Synchronizer Ring
19. Intermediate Ring
20. Outside Synchronizer Ring
21. Sliding Gear
22. 1st & 2nd Synchronizer Key
23. 1st & 2nd Synchronizer Spring
24. Washer
25. Circlip
26. 1st Speed Gear
27. Needle Cage28. Needle Cage
29. Main Shaft Disc
30. Retaining Ring
31. Groove Ball Bearing
32. Washer
33. Retaining Ring
34. 5th Speed Gear
35. Needle Cage
36. Synchronizer Ring
37. 5th Shift Sleeve
38. 5th Synchronizer Spring
39. 5th Synchronizer Key
40. Retaining Ring
41. Needle Sleeve
42. Input Drive Shift
43. Input Shaft Cluster Gear
44. Bolt
45. Retaining Ring
46. Cluster Bearing Ring
47. Groove Ball Bearing
48. Cluster 5th Speed Gear
49. Retaining Ring
50. Washer
51. Reverse Idler Gear
52. Reverse Idler Gear Shaft
53. Ball

FIVE–SPEED MANUAL TRANSAXLE 5B – 11
DAEWOO V–121 BL4
BEARING PLATE
1. Strain Bolt Bridge
2. Bolt
3. Bolt
4. Bolt
5. Bearing Plate
6. Bolt
7. Pin
8. Blocking Pin
9. Compression Spring
10. Plug
11. Gear Shift Sliding Fork12. GearShift Shoe
13. Screw
14. Transaxle Cover
15. Transaxle Cover Gasket
16. Magnet
17. Bearing Plate Gasket
18. Bolt
19. Bolt
20. Bolt
21. Screw
22. Detent Sleeve

5B – 12IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
DIFFERENTIAL GEAR
1. Differential Gear Housing
2. Differential Gear
3. Speedometer Drive Gear
4. Washer
5. Side Gear
6. Bevel Differential Gear
7. Bevel Gear Disc
8. Differential Gear Shaft
9. Differential Spring Pin
10. Bolt11. Taper Roller Bearing
12. Differential Bearing Ring
13. Shaft Seal Ring
14. O–Ring
15. Differential Gear Bearing Flange
16. O–Ring
17. Locking Plate
18. Bolt
19. Bolt

FIVE–SPEED MANUAL TRANSAXLE 5B – 13
DAEWOO V–121 BL4
SHIFT LINKAGE

5B – 14IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
1. Gear Shift Control
2. Bolt
3. Gear Shift Tube Bellows
4. Clamp
5. Bolt
6. Gear Shift Control Mode
7. Gear Shift Guide Control
8. Pin
9. Clip
10. Bolt
11. 1st & 2nd Gear Shift Fork
12. 1st & 2nd Gear Shift Rod
13. Pin
14. 3rd & 4th Gear Shift Fork
15. 3rd & 4th Gear Shift Rod
16. Pin
17. 5th Speed Engaging Piece
18. Gear Shift Rod Pawl
19. Reverse Gear Shift Fork
20. Reverse Gear Shift Rod
21. Pin
22. Gear Shift Rod
23. Shift Finger24. Gear Shift Lever Cover
25. Gear Shift Inter Lever
26. Plate
27. Compression Spring
28. Bush
29. Retaining Ring
30. Gear Shift Cover Gasket
31. Bolt
32. Plug
33. Plug
34. Speedometer Driven Gear
35. Bolt
36. Differential Gear Cover Gasket
37. Differential Gear Cover
38. Screw
39. Backup Lamp Switch
40. O–ring
41. Pin
42. Pin
43. Sleeve
44. Bush

FIVE–SPEED MANUAL TRANSAXLE 5B – 15
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CHECKING FLUID LEVEL
1. With the vehicle on a level surface and the fluid in
the transaxle cold, remove the filler plug and check
the fluid level. The fluid should come to the bottom
edge of the plug hole.
2. If the level is low, add SAE 80 manual transaxle
fluid through the filler plug hole until the fluid begins
to run out.
3. Reinstall the filler plug and tighten it securely.
4. If the fluid is contaminated, drain the oil after re-
moving the differential gear cover.
SHIFT LINKAGE ADJUSTMENT
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
Important : All the gears must be easy to engage when
the vehicle is stationary, the engine is running, and the
clutch is disengaged.
3. Loosen the rod clamp bolt.

5B – 16IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
4. Remove the adjustment hole plug from the shift
lever cover.
5. Turn the gearshift rod and fully insert a 5 mm (0.2
inch) gauge pin into the adjustment hole.
6. Remove the boot from the console.
7. Pull the boot upward to expose the shift control le-
ver mechanism.
8. Position the gearshift lever close to left side of the
NEUTRAL position.
9. Insert a 5 mm (0.2 inch) gauge pin into the holes to
align the gearshift lever with the gearshift lever
housing.
10. Tighten the rod clamp bolt.
Tighten
Tighten the rod clamp bolt to 14 NSm (124 lb–in).
11. Remove .the 5 mm (0.2 inch) gauge pin from the
adjustment hole.
12. Install the adjustment hole plug.
13. Remove the 5 mm (0.2 inch) gauge pin from the
gearshift lever.
14. Install the boot to the console.
15. Connect the negative battery cable.