DAEWOO LACETTI 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 57
DAEWOO V–121 BL4
8. Install the third–fourth gearshift rod/fork holding pin.
9. Install the support bracket onto the bearing plate.
10. Install the first–second gearshift rod/fork onto the
bearing plate.
11. Install the first–second gearshift fork holding pin.

5B – 58IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
12. Install the support bracket bolts.
Tighten
Tighten the support bracket bolts to 7 NSm (62 lb–in).
13. Install the reverse gearshift rod/fork onto the bear-
ing plate.
14. Install the reverse gearshift rod/fork holding pin.
15. Install the rod lock pin and spring into the small plug
hole.

FIVE–SPEED MANUAL TRANSAXLE 5B – 59
DAEWOO V–121 BL4
16. Install the fourth–gearshift rod plugs.
17. Install the bolts and the fifth–gearshift connector
onto the bearing plate, using the pawl.
Tighten
Tighten the fifth–gearshift connector bolts to 7 NSm
(62 lb–in).
18. Install the input drive fifth gear using the installer
KM–554 and the installer sleeve KM–334.
19. Install the snap rings securing the fifth–drive gear.

5B – 60IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
20. Install the thrust washers, the retaining ring, and
the needle bearing into the mainshaft–driven fifth–
gear assembly.
21. Install the brass synchronizer ring onto the main-
shaft– driven fifth–gear assembly.
22. Install the mainshaft–driven fifth–gear assembly.
23. Install the fifth–drive gear synchronizer gear and
the synchronizer sleeve using installer KM–554.
24. Install the snap ring holding the fifth speed–driven
assembly.

FIVE–SPEED MANUAL TRANSAXLE 5B – 61
DAEWOO V–121 BL4
25. Install the bolts and the fifth–gear fork onto the
bearing plate.
Tighten
Tighten the fifth–gear fork bolts to 22 NSm (16 lb–ft).
26. Remove the bearing plate from the fixture KM–552.
27. Shift the transaxle into second gear.
28. Install the bearing plate, with the shafts attached,
into the case.
29. Install the bearing plate bolts.
Tighten
Tighten the bearing plate bolts to 22 NSm (16 lb–ft).
30. Install the speedometer–driven gear and the
speedometer–housing retaining bolt into the trans-
axle housing.
Tighten
Tighten the speedometer housing retaining bolt to 4
NSm (35 lb–in).

5B – 62IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
31. Bolt the gearshift lever cover to the fixture KM–552.
32. Position the fixture into the base KM–113–2.
33. Install the gearshift rod, the shift finger lever, and
the gearshift lever pin.
34. Install the snap ring, the bushing, the spring, and
the intermediate lever.
35. Remove the gearshift lever cover from the base
KM–113–2 and the fixture KM–552.
36. Shift the transaxle into NEUTRAL.
37. Install the gearshift lever cover and the gearshift
lever cover bolts.
Tighten
Tighten the gearshift lever cover bolts to 22 NSm (16
lb–ft).
38. Install the transaxle cover and the transaxle cover
bolts.
Tighten
Tighten the transaxle cover bolts to 18 NSm (13 lb–ft).
39. Install the transaxle into the vehicle. Refer to
”Transaxle Assembly” in this section.

FIVE–SPEED MANUAL TRANSAXLE 5B – 63
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FIVE–SPEED MANUAL TRANSAXLE
This five–speed transaxle assembly is a transmission of
constant–mesh design.
Combined in the assembly are:
S All forward gears.
S The reverse gear.
S The differential output.
The basic components of the five–speed transaxle as-
sembly units are the:
S Transaxle case.
S Input shaft.
S Input shaft gears.S Output shaft.
S Output shaft gears.
S Ring gear and differential assembly.
Forward Gear
Shifting to a forward gear is accomplished through a com-
bination of synchronizers with blocker rings controlled by
sliding shift forks.
Reverse Gear
Reverse gear is not synchronized and uses a sliding idler
gear arrangement.
Differential Assembly
The differential is a conventional arrangement of gears
that is supported by tapered roller bearings. The final out-
put gear turns the ring gear and differential assembly
which turns the drive axle shafts.

SECTION : 5C
CLUTCH
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 terminals. 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
SPECIFICATIONS5C–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5C–1. . . . . . . . . . .
SPECIAL TOOLS5C–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5C–2. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5C–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Operation 5C–2. . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR5C–4 . . . . . . . . . . . . . . . . . . . .
Clutch Components 5C–4. . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR5C–6 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 5C–6. . . . . . . . . . . . . . . . . . . . .
Clutch Pedal 5C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Pedal Adjustment 5C–7. . . . . . . . . . . . . . . . . . . .
Clutch Release Point Adjustment 5C–8. . . . . . . . . . . .
Air Bleeding 5C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Plate and Clutch Disc 5C–8. . . . . . . . . . . . . .
Clutch Master Cylinder Assembly 5C–10. . . . . . . . . . .
Concentric Slave Cylinder 5C–12. . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION5C–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving Members 5C–14. . . . . . . . . . . . . . . . . . . . . . . . .
Driven Members 5C–14. . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Members 5C–14. . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Clutch Master Cylinder nuts2216–
Concentric Slave Cylinder Retaining Bolts7–62
Concentric Slave Cylinder–to–Clutch Oil Pipe Screw1511–
Pressure Plate–to–Flywheel Bolts1511–

5C – 2ICLUTCH
DAEWOO V–121 BL4
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–42474
Clutch Arbor
DIAGNOSIS
CLUTCH OPERATION
Intermittent Clutch Operation
ChecksAction
Check for the driver improperly operating the vehicle.Correct the driver’s operation of the vehicle as necessary.
Check for the improper clutch pedal play.Adjust the clutch pedal play.
Check for the insufficient oil or the leak at oil pressure line.Repair the leak or add the oil.
Check for a warped or worn clutch disc.Replace the clutch disc.
Check for worn splines on the input shaft.Repair or Replace the splines on the input shaft.
Check for a weak diaphragm spring.Replace the pressure plate.
Clutch Slipping
ChecksAction
Check for a stuck concentric slave cylinder.Replace the concentric slave cylinder.
Check for improper return of clutch oil.Perform the air bleeding.
Check for a worn clutch disc or oil contamination.Replace the clutch disc.
Check for a warped pressure plate.Replace the pressure plate.

CLUTCH 5C – 3
DAEWOO V–121 BL4
Clutch Vibration
ChecksAction
Check for a contaminated or warped flywheel.Repair or replace the flywheel.
Check for a weak diaphragm spring.Replace the pressure plate.
Check for a oily contamination of clutch disc.Replace the clutch disc.
Check for worn splines on the input shaft.Replace the splines on the input shaft.
Check for a warped pressure plate or flywheel.Replace the pressure plate or flywheel.
Hard Pedal Effort
ChecksAction
Check for bad lubrication of clutch pedal shaft.Apply the grease or repair it.
Check for a clogged pipe.Inspect or replace the clogged pipe.
Check for a stuck concentric slave cylinder.Replace the concentric slave cylinder.
Noise in Clutch Pedal
ChecksAction
Check for insufficient lubrication of clutch pedal bushing.Lubricate the clutch pedal bushing.
Check for interference of clutch pedal return spring.Remove and reinstall the clutch pedal return spring.