Reverse DAEWOO LACETTI 2004 Service Owner's Manual

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 221
DAEWOO V–121 BL4
6. Remove the axial needle bearing.
7. Take out front gear set with rear ring gear, front sun
gear and oil trays.
8. Take oil trays and front sun gear off the planetary
gear set.
9. Installation should follow the removal procedure in
the reverse order.
BRAKE C/D
Tools Required
DW260–160 Brake C/D Snap Ring Remover/Installer
Disassembly and Assembly Procedure
1. Take snap ring out of transaxle housing.

5A1 – 224IZF 4 HP 16 AUTOMATIC TRANSAXLE
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10. Turn the disc carrier C/D by 180°.
11. Using assembly bracket Press down cup spring and
take out the snap ring.
12. Remove the disc set D.
13. Installation should follow the removal procedure in
the reverse order.
DIFFERENTIAL
Disassembly and Assembly Procedure
1. Remove the torque converter housing. Refer to
”Torque Converter” in this section.
2. Lift out the differential.
3. Installation should follow the removal procedure in
the reverse order.
Removal Notice
S Don’t disassemble the differential to avoid incorrect
operation.
SIDE SHAFT
Disassembly and Assembly Procedure
1. Remove the differential. Refer to ”Differential” in
this section.
2. Tilt and remove the side shaft.
3. Installation should follow the removal procedure in
the reverse order.
Removal Notice
S Don’t disassemble the differential to avoid incorrect
operation.

5A1 – 226IZF 4 HP 16 AUTOMATIC TRANSAXLE
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5. Release the piston F by applying compressed air to
the bore.
6. Remove piston F and bearing plate with spur gear.
7. Installation should follow the removal procedure in
the reverse order.
Removal Notice
Since the bearing set is tight, press the bearing plate up-
ward from underneath to remove it.
ORIGIN
ON/OFF– 12.54
+ / –
ORIGIN
ON/OFF– 12.54
+ / –
Tools Required
DW 260–110 Brake F Disc Clearance Measuring Bar
Measuring Installation Space F
1. Using a depth gauge, measuring from the transaxle
housing sealing surfaces to the piston’s disc sup-
port surface at two opposing points = M1, M2
2. Average the measurement values M1, M2 = BF
S CALCULATION
BF = (M1+M2)/2
S CALCULATION
M1 = 18.6mm
M2 = 18.8mm
BF = 18.7mm
Determining Adjusting Disc F
1. Calculate the test dimension PF (PF = BF – MF)
BF = installation space
MF = disc set thickness (assume 14.50mm)
S EXAMPLE
BF = 18.70mm
MF = 14.50mm
PE = 4.2mm

5A1 – 228IZF 4 HP 16 AUTOMATIC TRANSAXLE
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7. Remove the baffle plate bolts and baffle plate.
Installation Notice
Tighten
Tighten the baffle plate bolts to 10 NSm (89 lb–in).
8. Remove the line pressure measurement plug.
9. Installation should follow the removal procedure in
the reverse order.
Installation Notice
Tighten
Tighten the line pressure measurement plug to 20
NSm (15 lb–ft).
SHIFT MECHANISM
Disassembly and Assembly Procedure
1. Take out the select shaft clamping sleeve.
2. Remove the shift mechanism.
S Shift mechanism is consist of select shaft, det-
ent disc, connecting bar, stop bush.
3. Installation should follow the removal procedure in
the reverse order.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 229
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PARKING LOCK SYSTEM
Disassembly and Assembly Procedure
1. Remove the parking lock assembly.
S Parking lock system is consist of parking pawl,
leg spring, support bolt.
2. Installation should follow the removal procedure in
the reverse order.
BEARING PLATE(WITH SPUR GEAR)
ASSEMBLY
Disassembly and Assembly Procedure
1. Remove the piston F. Refer to ”Brake F” in this
section.
2. Remove the bearing plate bolts and bearing plate.
3. Installation should follow the removal procedure in
the reverse order.
Installation Notice
Tighten
Tighten the bearing plate bolts to 27 NSm (17 lb–ft).
OIL PUMP ASSEMBLY
Disassembly and Assembly Procedure
1. Remove the oil pump housing bolts.
2. Using the plastic hammer. Take out the oil pump
housing.
Installation Notice
Tighten
Tighten the oil pump housing bolts 10 NSm (89 lb–in).
3. Remove the stator shaft bolts.

5A1 – 230IZF 4 HP 16 AUTOMATIC TRANSAXLE
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4. Dismantle the oil pump gear, ring gear
5. Installation should follow the removal procedure in
the reverse order.
DIFFERENTIAL/SIDE SHAFT OUTER
RACE, BEARING SHIM
Disassembly and Assembly Procedure
1. Take out the outer race of the transaxle housing
side.
2. Remove the bearing shim.
3. Take out the outer race of the torque converter
housing side.
Installation Notice
S Heat the bearing seats well and insert bearing outer
rings with shim for differential and side shaft into
the transaxle housing.
IMPORTANT
MEASUREMENT/ADJUSTMENT
Tools Required
DW260–080 Clutch B/E Shim Setting Gauge
Adjusting Axial Play, Input Shaft
Important : After assembling the rear cover. You must
measure the axial play specification, if the measured data
is not satisfied the specification. Replace the clutch B/E’s
shim.
Incorrect axial play may cause the vibration or noise. The
specification of the axial play is 0.18 to 0.42mm.
1. Clamp fixture on the input shaft so that the measur-
ing base rests on the stator shaft.
2. Set dial gauge to zero.
3. Measure axial play by pulling and pressing on the
handle.(repeat measurement)

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 233
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To engage the lock–up clutch, the direction of flow is modi-
fied (reversed) via a valve in the hydraulic selector unit. At
the same time, the space behind the lock–up clutch piston
is vented. The oil pressure passes from the turbine cham-
ber to the lock–up clutch piston and presses it against the
converter’s cover. The turbine is thus blocked by way of
the linings between the piston and cover, and permits rigid
through drive with no slip (or reduced slip if controlled) to
the mechanical stage of the transaxle.
Fluid Pump
The fluid pump is located between the torque converter
and the transaxle case and is driven directly by the torque
converter. The pump sucks the fluid through a filter and de-
livers it to the main pressure regulator valve of the control
system. Excess fluid flows back to the pump. The fluid
pump fulfills the following functions:
S Generates line pressure.
S Delivers fluid under pressure to the torque convert-
er, thus preventing air bubbles in the fluid.
S Induces a flow of fluid through the torque converter
in order to eliminate heat.
S Supplies fluid pressure to the hydraulic control sys-
tem.
S Supplies fluid pressure to the shift components.S Lubricates the transaxle with fluid.
Pump Housing
1. Disc
2. Shaft seal
3. Stator shaft
4. Pump wheel
5. Pump ring gear
6. Dowel pin
Planetary Gears
The ZF 4HP 16 automatic transaxle is equipped with a one
sun gear, 4 planetary gears, planetary carrier, ring gear.
Each gear is located one directly behind the other and are
linked together. In other words, front ring gear is perma-
nently linked to rear planet carrier, front planet carrier is
linked to rear ring gear.
The individual gear ratios are obtained by linking together
the gear set elements in different ways by means of
clutches and brakes.
On the 4HP 16, the power flow is directed into the plane-
tary gear set via rear planet carrier or rear sun gear, or via
both simultaneously, depending on the gear in question.
The output is always via the front planet carrier.

5A1 – 236IZF 4 HP 16 AUTOMATIC TRANSAXLE
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ELECTRONICAL COMPONENTS
Selector Lever/Program Switch
The driver engages the travel position via the selector le-
ver:
P : Park Position
R : Reverse
N : Neutral
D : Forward Speeds
Park/Neutral Position Switch
The Park/Neutral Position Switch is located on the selec-
tor shaft and informs the TCM of the current selector lever
position P–R–N–D–3–2–1.
The selector lever position is transmitted to the TCM in en-
coded form along 4 lines. The encoding is such that mal-
functions in the connecting lead are identified.
The Park/Neutral Position Switch is located on the selec-
tor shaft, which is connected to the selector lever via a pull
cable. In addition, the Park/Neutral Position Switch con-
trols the starter interlock, the reversing light and the selec-
tor lever position indicator on the instrument panel.
Signal Combination
L1L2L3L4
P00120
R00012
N01200
D1212120
31212012
21201212
10121212
Automatic Transaxle Output Speed Sensor
(A/T OSS)
The vehicle A/T OSS is a magnetic inductive pickup that
relays information relative to vehicle speed to the TCM.
Vehicle speed information is used by the TCM to control
shift timing, line pressure, and TCC (lock–up clutch) apply
and release.
The output speed sensor mounts in the case at the speed
sensor rotor, which is pressed onto the spur gear. An air
gap of 0.1mm~1.3mm(0.004~0.05in) is maintained be-
tween the sensor and the teeth on the spur gear teeth. The
sensor consists of a permanent magnet surrounded by a
coil of wire.
As the differential rotates, an AC signal is generated by the
output speed sensor (OSS).
Automatic Transaxle Input Speed Sensor
(A/T ISS)
The A/T ISS is a magnetic inductive pickup that relays in-
formation relative to transaxle input speed to the TCM.
The TCM uses transaxle input speed information to con-
trol line pressure, TCC apply and release and transaxle
shift patterns. This information is also uses to calculate the
appropriate operating gear ratios and TCC slippage.
The input speed sensor mounts onto piston B that is inside
of valve body.
An air gap of 1.8~2.2mm(0.07~0.086inch) is maintained
between the sensor and the piston B.
The sensor consists of a permanent magnet surrounded
by a coil of wire. As the piston B is driven by the turbine
shaft, an AC signal induced in the input speed sensor.
Higher vehicle speeds induce a higher frequency and volt-
age measurement at the sensor.
Sensor resistance should measure between 825~835
ohms at 20°C (68°F). Sensor can measure from
1,000~8,000HZ.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 237
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Shift Solenoid Valve: Solenoid 1,2
The shift solenoids are two identical, normally open elec-
tronic exhaust work that control upshifts and downshifts in
all forward gear ranges. These shift solenoids valves to-
gether in a combination of ON and OFF sequences to con-
trol the line pressure and shift mechanisms (clutches,
brakes).
Solenoid 1 controls the high or low of the line pressure
(flow to each clutch valve) by the operation type (ON/
OFF), i.e. solenoid 1is ON, line pressure will be low
(87~116 psi (6~8bar)), solenoid 1 is OFF, line pressure will
be high (232~261 psi (16~18bar)).
Solenoid 2 controls the oil flow to clutch valve E or lockup
clutch valve by the ON/OFF signal.
The TCM monitors numerous inputs to determine the ap-
propriate solenoid state combination and transaxle gear
for the vehicle operating conditions.
Gear
Solenoid 1Solenoid 2
Park, NeutralONON
FirstON/OFFON
SecondON/OFFOFF
ThirdON/OFFOFF
FourthON/OFFOFF
ReverseON/OFFON
Line PressureResistance
Solenoid
valve 1/Sole-
noid valve 2ON(low)
89.9~98.6 psi
(6.2~6.8 bar)
OFF(high)
S 221.9~253.24
psi
S (15.3~17.46
bar)26.5 ± 0.5ohm
Pressure Control Solenoid Valve (EDS
VALVE 3,4,5,6)
The pressure control valve (EDS valve 3,4,5,6) is a preci-
sion electronic pressure regulator that controls the opera-
tion of the clutches, brakes and the lock–up clutch.
The valve reduces the system pressure with which the
downstream solenoid valves and electrical pressure regu-
lating valves are supplied. It is possible to use smaller so-
lenoid valves as a result. The EDS require a constant input
pressure.

5A2 – 2IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Shift Control Lever Assembly 5A2–100. . . . . . . . . . . . .
Transmission Range (TR) Switch 5A2–101. . . . . . . . .
Shift Control Cable 5A2–104. . . . . . . . . . . . . . . . . . . . . .
Shift Select Cover 5A2–105. . . . . . . . . . . . . . . . . . . . . .
Input Shaft Speed (ISS) Sensor 5A2–106. . . . . . . . . .
Output Shaft Speed (OSS) Sensor 5A2–107. . . . . . . .
Transmission Control Module (TCM) 5A2–108. . . . . .
Fluid Cooler Inlet Pipes and Hoses 5A2–109. . . . . . . .
Fluid Cooler Outlet Pipes and Hoses 5A2–110. . . . . .
Transaxle Assembly 5A2–111. . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 5A2–117. . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Disassembly 5A2–117. . . . . . . . . . .
Major Component Assembly 5A2–137. . . . . . . . . . . . .
Oil Pump 5A2–167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Clutch 5A2–171. . . . . . . . . . . . . . . . . . . . . . . . . . .
Planetary Ring Gear 5A2–178. . . . . . . . . . . . . . . . . . . .
One–Way Clutch 5A2–180. . . . . . . . . . . . . . . . . . . . . . .
Forward and Reverse Clutch 5A2–183. . . . . . . . . . . . .
Counter Driven Gear 5A2–192. . . . . . . . . . . . . . . . . . . .
Valve Body 5A2–195. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Case 5A2–208. . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION5A2–218 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transaxle Description 5A2–218. . . . . . . . . . . . . . . . . . .
Electronical Components 5A2–218. . . . . . . . . . . . . . . .
Hydraulic Control System 5A2–221. . . . . . . . . . . . . . . .
Automatic Transaxle System 5A2–222. . . . . . . . . . . . .