Brake DAEWOO LACETTI 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 29
DAEWOO V–121 BL4
Result of Time Lag TestCause of Failure
Longer than standards ”N”  ”D”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Forward Clutch (C1) failure (Slipping)
Timing solenoid failure
Oil leak for ”D” range circuit
Longer than standards ”N”  ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Reverse clutch (C3) failure (slipping)
1st & reverse brake (B3) failure (slipping)
Oil leak for ”R” range circuit
Hydraulic Test
Hydraulic test can inspect working condition inside A/T by
measuring line pressure in ”D” / ”R” range and ”idle” / ”stall”
condition.
1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.2. Install oil pressure gage adapter DW240–010–02 to
test hole for line pressure.
3. Fully pressed on foot brake pedal with left foot, shift
into ”D” and ”R” range and measure line pressure
”idle” / ”stall” condition.
Line pressure
Mpa (kgf/cm
2)
DR
Engine idle0.37 (3.9)
–0.14 (4.2)0.59 (6.0)
–0.68 (6.9)
Engine stall1.10 (11.3)
–1.23 (12.5)1.58 (16.2)
–1.83 (18.6)
Notice : Do not continuously run longer than 5 sec be-
cause of extreme increasing oil temp.
Make sure to keep interval for more than 1 min between
stall tests.
Make sure to check no oil leak after installing oil pressure
gage adapter.
Result of Hydraulic Test
Cause of Failure
Higher than standards
both ”D and ”R”Pressure control solenoid (PCS) failure
Primary regulator valve failure
Lower than standards
both ”D and ”R”Pressure control solenoid (PCS) failure
Primary regulator valve failure
Oil pump failure
Oil strainer failure (clogging)
Oil leak for each range circuit
Lower than standards
only ”D”D” hydraulic circuit failure
Forward clutch (C1) failure
Lower than standards
only ”R””R” hydraulic circuit failure
Reverse clutch (C3) failure
1st and reverse brake (B3) failure

AISIN AUTOMATIC TRANSAXLE 5A2 – 117
DAEWOO V–121 BL4
UNIT REPAIR
MAJOR COMPONENT DISASSEMBLY
Tools Required
DW240–020 Brake/Clutch Spring Compressor
DW240–050 Overdrive Brake Adapter
DW240–060–01 Brake Spring Compressor Bolt/Nut
DW240–070 1st & Reverse Brake Adapter
DW240–080 2nd Brake Adapter
DW240–090 Planetary Ring Gear Remover
DW240–150 Transaxle Case Side Bearing Outer Race
Adapter
DW240–170 Adapter Handle
DW260–021–02 Automatic Transaxle Overhaul Fixture
(81–40 LE)
DW260–041 Planetary Ring Gear Nut Removal/Installa-
tion Socket
Disassembly Procedure
1. Remove the transaxle assembly from the vehicle.
Refer to”Transaxle Assembly” in this section.
2. Install the transaxle assembly to the transaxle sup-
port stand using Automatic Transaxle Overhaul Fix-
ture DW260–021–02 (81–40 LE).
3. Remove the nut, washer and control lever.
4. Using a screwdriver, unstake the lock washer.
5. Remove the two bolts and nut and pull out the
transmission range (TR) switch.
6. Remove the two unions the transaxle case.
7. Remove the two O–rings from the unions.

5A2 – 120IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
22. Disconnect the manual valve control rod from the
manual valve lever, then remove the valve body
assembly.
23. Remove the check valve and spring.
24. Remove the brake drum gasket.
25. Remove the apply gasket.

5A2 – 122IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
Notice : Blowing off the air may cause the piston’s jump–
out.When removing the piston, hold it with your hand using
a waste cloth.
Notice : Take care not to splash ATF when air–blowing.
32. Apply 392 kPa (57 psi) of compressed air to the oil
hole and remove the O/D & 2nd brake (B1) clutch
accumulator piston and spring.
33. Remove the 2 O–rings from the O/D & 2nd brake
(B1) accumulator piston.
34. Remove the bolt and the transaxle wire from the
transaxle case.
35. Remove the O–ring from the transaxle wire.

AISIN AUTOMATIC TRANSAXLE 5A2 – 125
DAEWOO V–121 BL4
44. Remove the counter driven gear assembly from the
transaxle case.
45. Remove the 9 bolts and tap on the circumference
of the transaxle rear cover with a plastic hammer to
remove the transaxle rear cover from the transaxle
case.
46. Remove the 4 apply gaskets.
47. Remove 2nd coast & O/D brake (B1) flange, 2
discs and 2 plates from the transaxle case.

5A2 – 128IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
56. Remove the front planetary sun gear from the
transaxle case.
57. Remove the thrust bearing race from the front plan-
etary sun gear.
WARNING : USE CAUTION WHEN REMOVING SNAP
RINGS OR PERSONAL INJURY MAY RESULT.
Notice : Stop the press when the 2nd brake is lowered 1–
2 mm (0.039–0.078 in.) from the snap ring groove, pre-
venting the 2nd brake from being deformed.
58. Using brake spring compressor bolt/nut
DW240–060–01 and 2nd brake adapter
DW240–080, remove the 2 snap rings, 2nd brake
piston and 2nd brake piston return spring.
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
Notice : Blowing off the air may cause the piston’s jump–
out.When removing the piston, hold it with your hand using
a waste cloth.
Notice : Take care not to splash ATF when air–blowing.
59. Apply 392 kPa (57 psi) of compressed air to the
2nd brake to remove the 2nd brake piston from the
2nd brake clutch cylinder.
60. Remove the 2 O–rings from the 2nd brake piston.

5A2 – 132IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
73. Using a screwdriver, remove the oil seal.
74. Using brake spring compressor bolt/nut
DW240–060–01, 1st & reverse brake adapter
DW240–070 and planetary ring gear remover
DW240–090, remove the planetary ring gear.
75. Install the 3 bolts to the counter drive gear.
S Bolt (M6) : L= 40–80mm, Pich = 1.0mm
76. Rotate 3 bolts in order and remove the counter
drive gear and planetary ring gear.
WARNING : USE CAUTION WHEN REMOVING SNAP
RINGS OR PERSONAL INJURY MAY RESULT.
77. Using brake spring compressor bolt/nut
DW240–060–01 and 1st & reverse brake adapter
DW240–070, remove the snap ring of 1st & reverse
brake.

AISIN AUTOMATIC TRANSAXLE 5A2 – 133
DAEWOO V–121 BL4
78. Remove the flange, 4 discs, 4 plates and return
spring.
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
Notice : Blowing off the air may cause the piston’s jump–
out. When removing the piston, hold it with your hand us-
ing a waste cloth.
Notice : Take care not to splash ATF when air–blowing
79. Apply 392 kPa (57 psi) of compressed air to the
transaxle case to remove the 1st & reverse brake
piston.
80. Remove the 2 O–rings from the 1st & reverse
brake piston.
81. Remove the bolt and No.1 transaxle case plate
from the transaxle case.

AISIN AUTOMATIC TRANSAXLE 5A2 – 135
DAEWOO V–121 BL4
88. Using a suitable puller, remove the counter driven
gear outer tapered roller bearing race from the
transaxle housing.
89. Using a driver, remove the oil seal from the trans-
axle housing.
Notice : Be careful not to damage the transaxle housing
when removing the oil seal using a driver.
90. Using a suitable puller, remove the side bearing
outer race from the transaxle housing.
WARNING : USE CAUTION WHEN REMOVING SNAP
RINGS OR PERSONAL INJURY MAY RESULT.
Notice : Stop the press when the O/D brake piston is low-
ered 1–2 mm (0.039–0.078 in.) from the snap ring groove,
preventing the O/D brake piston from being deformed.
91. Using brake/clutch spring compressor DW240–020,
overdrive brake adapter DW240–050 and a driver,
remove the snap ring.
92. Remove the O/D brake return spring.

5A2 – 136IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
Notice : Blowing off the air may cause the piston’s jump–
out.When removing the piston, hold it with your hand using
a waste cloth.
Notice : Take care not to splash ATF when air–blowing.
93. Apply 392 kPa (57 psi) of compressed air to the
transaxle rear cover to remove the O/D brake pis-
ton.
94. Remove the 2 O–rings from the O/D brake piston.
95. Remove the 2 seal rings from the transaxle rear
cover.
Notice : Do not expand the seal ring excessively.
96. Remove the 4 screw plugs and 4 O–rings from the
transaxle rear cover.