speedometer DAEWOO LACETTI 2004 Service User Guide

SECTION : 5B
FIVE–SPEED MANUAL 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 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
SPECIFICATIONS5B–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5B–2. . . . . . . . . . .
SPECIAL TOOLS5B–3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5B–3. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5B–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Isolate Noise 5B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis 5B–6. . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATORS5B–9 . . . . . . . . . . . . . . . . . .
Gears and Case 5B–9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Plate 5B–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Gear 5B–12. . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Linkage 5B–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR5B–15 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 5B–15. . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 5B–15. . . . . . . . . . . . . . . . . . . . . .
Shift Linkage Adjustment 5B–15. . . . . . . . . . . . . . . . . . Gearshift Lever 5B–17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearshift Lever Housing 5B–18. . . . . . . . . . . . . . . . . . .
Speedometer Driven Gear 5B–18. . . . . . . . . . . . . . . . .
Shift Linkage Assembly 5B–19. . . . . . . . . . . . . . . . . . . .
Drive Axle Seal 5B–20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Transaxle Assembly 5B–21. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 5B–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Disassembly 5B–26. . . . . . . . . . . . .
Input Shaft and Cluster Gear 5B–35. . . . . . . . . . . . . . .
Mainshaft 5B–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Case 5B–48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential 5B–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Assembly 5B–56. . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION5B–63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Five–Speed Manual Transaxle 5B–63. . . . . . . . . . . . . .

5B – 2IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Backup Lamp Switch2015–
Bearing Plate Bolts2216–
Bearing Retainer Bolts, Right Side2518–
Bearing–Adjusting Ring–Retainer Plate Bolt5–44
Clutch–Release Cylinder Retaining Bolts2015–
Damping Block Connection Nut and Bolt6850–
Differential Cover Bolts4030–
Fifth–Gear Fork Bolts2216–
Fifth–Gearshift Connector Bolts7–62
Flywheel Inspection Cover Bolts7–62
Gearshift Housing Bolts7–62
Gearshift Lever Cover Bolts2216–
Input Driveshaft Detent Screw1511–
Rear Damping Block Retaining Bolts6850–
Rear Mounting Bracket Bolts9066–
Ring–Gear Bolts7052–
Rod Clamp Bolt14–124
Speedometer Housing Retaining Bolt4–35
Speedometer–Driven Gear Bolt5–44
Transaxle Cover Bolts1813–
Transaxle Lower Retaining Bolts(a)7354–
Transaxle Lower Retaining Bolt(b)3123–
Transaxle Lower Retaining Bolts(c)2115–
Transaxle Upper Retaining Bolts7354–
Transaxle Upper Mounting Bracket Bolts4835–

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

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

5B – 18IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
GEARSHIFT LEVER HOUSING
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the rod clamp. Refer to ”Shift Linkage Ad-
justment” in this section.
3. Remove the console.
4. Remove the gearshift lever housing bolts and the
gearshift lever housing.
Installation Procedure
1. Install the gearshift lever housing and the gearshift
lever housing bolts.
Tighten
Tighten the gearshift housing bolts to 7 NSm ( 62 lb–
in).
2. Adjust the shift linkage.
3. Install the console.
4. Connect the negative battery cable.
SPEEDOMETER DRIVEN GEAR
Removal Procedure
1. Disconnect the speedometer speed sensor electri-
cal connector.
2. Remove the speedometer housing retaining bolt.
3. Remove the speedometer–driven gear and the
speedometer housing.

FIVE–SPEED MANUAL TRANSAXLE 5B – 19
DAEWOO V–121 BL4
Installation Procedure
1. Coat the O–ring with petroleum jelly.
2. Install the speedometer–driven gear and the
speedometer housing.
3. Install the speedometer housing retaining bolt.
Tighten
Tighten the speedometer housing retaining bolt to 4
NSm (35 lb–in).
4. Connect the speedometer speed sensor electrical
connector.
SHIFT LINKAGE ASSEMBLY
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the rod clamp. Refer to ”Shift Linkage Ad-
justment” in this section.
3. Remove the clip and the bolt from universal joint.
4. Separate the universal joint from the transaxle.
5. Remove the fixing shaft pin and separate the link-
age connection part from the transaxle rear mount-
ing bracket.
6. Remove the shift linkage assembly.

FIVE–SPEED MANUAL TRANSAXLE 5B – 21
DAEWOO V–121 BL4
TRANSAXLE ASSEMBLY
Tools Required
J–28467–B Engine Support Fixture
Removal Procedure
1. Install the engine support fixture J–28467–B.
2. Remove the battery and battery tray. Refer to Sec-
tion 1E, ENGINE ELETRICAL.
3. Remove the shift linkage assembly. Refer to ”Shift
Linkage Adjustment” in this section.
4. Remove the drive axle shaft. Refer to Section 3B,
Manual Transaxle Drive Axle.
5. Disconnect the backup lamp switch electrical con-
nector.
6. Disconnect the speedometer speed sensor electri-
cal connector.
7. Remove the pin and the clutch release cylinder
pipe.
8. Remove the damping block connection nut and
bolt.
9. Remove the three rear mounting bracket bolts.
10. Remove the rear mounting bracket from the trans-
axle.

FIVE–SPEED MANUAL TRANSAXLE 5B – 25
DAEWOO V–121 BL4
11. Connect the clutch release cylinder pipe.
12. Connect the speedometer speed sensor electrical
connector.
13. Connect the backup lamp switch electrical connec-
tor.
14. Remove the engine support fixture J–28467–B.
15. Install the drive axle shaft. Refer to Section 3B,
Manual Transaxle Drive Axle.
16. Install the shift linkage assembly. Refer to ”Shift
Linkage Assembly” in this section.
17. Install the battery and battery tray. Refer to Section
1E, ENGINE ELETRICAL.
18. Inspect the fluid level. Refer to ”Checking Fluid Lev-
el” in this section.

5B – 28IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
10. Remove the bolt and the speedometer–driven gear
from the transaxle housing.
11. Remove the transaxle cover bolts.
12. Remove the transaxle cover.
13. Shift the transaxle into second gear.
14. Remove the bearing plate bolts.

FIVE–SPEED MANUAL TRANSAXLE 5B – 49
DAEWOO V–121 BL4
7. Remove the clutch–release bearing and the clutch–
release bearing guide. Refer to Section 5C, Clutch.
8. Remove the speedometer–driven gear bolt and the
speedometer–driven gear from the transaxle hous-
ing.
Assembly Procedure
1. Install the speedometer–driven gear bolt and the
speedometer–driven gear into the transaxle hous-
ing.
Tighten
Tighten the speedometer–driven gear bolt to 5 NSm
(44 lb–in)
2. Install the clutch–release bearing guide and the
clutch–release bearing. Refer to Section 5C,
Clutch.
3. Install the backup lamp switch into the transaxle
housing.
Tighten
Tighten the backup lamp switch to 20 NSm (15 lb–ft).
4. Install the differential into the transaxle housing.
Refer to ”Differential” in this section.
5. Install the bearing plate, with the shafts attached.
6. Install the bearing plate bolts.
Tighten
Tighten the bearing plate bolts to 22 NSm (16 lb–ft).