DAEWOO LACETTI 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 37
DAEWOO V–121 BL4
MAINSHAFT
Tools Required
J–22912–01 Universal Bearing Puller
Disassembly Procedure
1. Remove the mainshaft bearing using the universal
bearing puller J–22912–01.
2. Remove the snap ring.
3. Remove the first gear, the flat–type first–gear
needle bearing, and the mainshaft wear plate.
4. Remove the synchronizer hub sleeve that contains
the synchronizer spring.
5. Remove the outer blocking ring.

5B – 38IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
6. Remove the keys from the first–second synchroniz-
er gear.
7. Remove the barrel–type first–gear needle bearing.
8. Remove the snap ring and the washer.
9. Remove the first–second synchronizer gear from
the mainshaft.

FIVE–SPEED MANUAL TRANSAXLE 5B – 39
DAEWOO V–121 BL4
10. Remove the first–second gear blocking ring.
11. Remove the second gear using the universal bear-
ing puller J–22912–01.
12. Remove the second–gear needle bearing.
13. Remove the ring and the thrust washer.

5B – 40IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
14. Remove the third gear and the synchronizer block-
ing ring.
15. Separate the synchronizer blocking ring from the
third gear.
16. Remove the third–gear needle bearing from the
mainshaft.
17. Remove the synchronizer sleeve containing the
keys and the spring.

FIVE–SPEED MANUAL TRANSAXLE 5B – 41
DAEWOO V–121 BL4
18. Remove the snap ring and the washer from the
mainshaft.
19. Remove the third–fourth synchronizer gear contain-
ing the synchronizer spring.
20. Remove the fourth–gear assembly.
21. Separate the synchronizer blocking ring from the
fourth gear.

5B – 42IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
22. Remove the fourth–gear needle bearing, the ring,
and the thrust washer.
23. Remove the mainshaft bearing.
Assembly Procedure
1. Install the mainshaft bearing.
2. Install the ring, the thrust washer, and the fourth–
gear needle bearing.

FIVE–SPEED MANUAL TRANSAXLE 5B – 43
DAEWOO V–121 BL4
3. Attach the synchronizer blocking ring to the fourth
gear.
4. Install the fourth–gear assembly.
5. Install the third–fourth gear synchronizer containing
the synchronizer spring.
6. Install the snap ring and the washer around the
mainshaft.

5B – 44IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
7. Install the synchronizer sleeve containing the keys
and the spring.
8. Install the third–gear needle bearing.
9. Attach the synchronizer blocking ring to the third
gear.
10. Install the third–gear assembly.

FIVE–SPEED MANUAL TRANSAXLE 5B – 45
DAEWOO V–121 BL4
11. Install the thrust washer and the ring.
12. Install the second–gear needle bearing.
13. Install the second gear.
14. Install the first–second gear blocking ring.

5B – 46IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
15. Install the first–second synchronizer gear.
16. Install the washer and the snap ring.
17. Install the first–gear needle bearing.
18. Install the keys onto the first–second synchronizer
gear.