Brake DAEWOO LACETTI 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 229
DAEWOO V–121 BL4
D–3rd Gear
PositionSolenoidClutchBrake1 way
Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
D3rdOFFOFFOFFONONOFFOFFONOFFOF
–FOF
–F
”D” – 3rd Gear
1. Input shaft rotates clockwise.
S Forward clutch (C1) operates. (Connect input shaft to front sun gear)
S Direct clutch (C2) operates. (Connect input shaft to planetary carrier)
2. Planetary short pinion and planetary long pinion can not rotate itself, and planetary gear unit rotates clockwise as
one.
3. Counter drive gear rotates clockwise for ring gear and one.
4. Counter drive gear rotates counterclockwise

5A2 – 230IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
5. Differential drive pinion rotates counterclockwise for counter driven gear and one.
6. Differential rotates clockwise.
( Engine Brake)
Driving force is connected to input shaft directory without 1 way clutch.
Therefore Engine Brake operates.

AISIN AUTOMATIC TRANSAXLE 5A2 – 231
DAEWOO V–121 BL4
D–4th Gear
PositionSolenoidClutchBrake1 way
Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
D4thOFFONOFFOFFONOFFONONOFFOF
–FOF
–F
”D” – 4th Gear
1. Input shaft rotates clockwise.
S Direct clutch (C2) operates. (Connect input shaft to planetary carrier)
2. Planetary carrier revolves clockwise.
3. Planetary long pinion rotates itself clockwise.
4. Rear planetary sun gear is going to rotate counterclockwise.
S O/D & 2nd brake (B1) operates. (Lock rotates planetary sun gear)
5. Planetary long pinion revolves clockwise while rotating itself clockwise.
6. Ring gear rotates clockwise.
7. Counter drive gear rotates clockwise for ring gear and one.

5A2 – 232IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
8. Counter driven gear rotates counterclockwise.
9. Differential gear drive pinion rotates counterclockwise for counter driven gear and one.
10. Differential gear rotates clockwise.
( Engine Brake)
Driving force is connected to input shaft directory without 1 way clutch.
Therefore Engine Brake operates.

AISIN AUTOMATIC TRANSAXLE 5A2 – 233
DAEWOO V–121 BL4
Reverse Gear
PositionSolenoidClutchBrake1 way
Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
RV<9
km/
hONONONOFFOFFONOFFOFFONOF
–FOF
–F
V
9km
/hONONONOFFOFFOFFOFFOFFOFFOF
–FOF
–F
Reverse Gear
1. Input shaft rotates clockwise.
S Reverse clutch (C3) operates.(Connect input shaft to rear planetary sun gear)
2. Planetary long pinion rotates itself counterclockwise.
3. 1st & reverse brake(3) operates. (Lock rotates planetary carrier)
4. Ring gear rotates counterclockwise.

5A2 – 234IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
5. Counter drive gear rotates counterclockwise for ring gear and one.
6. Counter driven gear rotates clockwise.
7. Differential gear drive pinion rotates clockwise for counter driven gear and one.
8. Differential gear rotates counterclockwise.
(Engine Brake)
Driving force is connected to input shaft directory without 1 way clutch.
Therefore Engine Brake operates.

5C – 8ICLUTCH
DAEWOO V–121 BL4
CLUTCH RELEASE POINT
ADJUSTMENT
Adjustment Procedure
1. Apply the parking brake.
2. Run the engine at idle speed.
3. While you move the shift lever into the reverse
position, depress the clutch pedal slowly and mea-
sure the distance between the point when gear
noise is not heard and the point the clutch pedal is
completely depressed. The distance should be 30
to 40 mm (1.2 to 1.6 inches).
4. If the distance is not within the specified value,
check the following:
S Clutch pedal height
S Clutch pedal play
S Air in the system
S Clutch cover and disc pressure plate
AIR BLEEDING
Bleed the hydraulic system to remove the air which en-
tered when the pipes were disconnected for repairs. The
clutch/brake fluid in the clutch/brake reservoir must be
maintained at the MIN level or higher during air bleeding.
1. Attach a vinyl hose to the bleeder plug. Place the
other end of the vinyl tube in a glass container half–
filled with brake fluid.
2. Slowly pump the clutch pedal several times.
3. While you press the clutch pedal, loosen the bleed-
er screw until the fluid starts to run out. Close the
bleeder screw.
4. Repeat Step 3 until there are no air bubbles in the
fluid.
5. Fill the reservoir with brake fluid up to the proper
level.
PRESSURE PLATE AND CLUTCH
DISC
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the transaxle from the vehicle. Refer to
Section 5B, Five–Speed Manual Transaxle.
3. Remove the pressure plate bolts and the pressure
plate.
Important : Support the pressure plate when you remove
the last bolt.

5C – 10ICLUTCH
DAEWOO V–121 BL4
Installation Procedure
1. Coat the spline on the clutch disc with multi–pur-
pose grease.
2. Align the pressure plate and the clutch disc onto
the flywheel using the clutch arbor J–42474.
3. Install the pressure plate bolts.
Tighten
Tighten the bolts to 15 NSm (11 lb–ft).
4. Remove the clutch arbor J–42474.
5. Install the transaxle into the vehicle. Refer to Sec-
tion 5B, Five–Speed Manual Transaxle.
6. Connect the negative battery cable.
CLUTCH MASTER CYLINDER
ASSEMBLY
Removal Procedure
Before disconnecting the reservoir tank hose, remove the
clutch/brake fluid from the reservoir tank.
1. Remove the locking clip.
2. Remove the push rod fixing pin and push rod.
3. Disconnect the hose clamp on the master cylinder.
4. Disconnect the master cylinder hose.
5. Remove the master cylinder pipe.

5C – 12ICLUTCH
DAEWOO V–121 BL4
5. Install the push rod fixing pin and push rod.
6. Install the locking clip.
7. Bleed the air. Refer to ”Air Bleeding” in this section.
8. Adjust the clutch pedal. Refer to ”Clutch Pedal Ad-
justment” in this section.
9. Fill the reservoir with clutch/brake fluid up to the
proper level.
CONCENTRIC SLAVE CYLINDER
Removal Procedure
1. Remove the transaxle from the vehicle. Refer to
Section 5B, Five–Speed Manual Transaxle.
2. Remove the concentric slave cylinder retaining
bolts.
3. Disconnect the concentric slave cylinder pipe from
the concentric slave cylinder.
Notice : When removing the bushing, Make sure not to re-
move it with excessive force.
4. Remove the bushing from the concentric slave cyl-
inder pipe in the transaxle housing.
5. Remove the concentric slave cylinder pipe.
Notice : For removal or installation, Make sure not to sep-
arate oil seal fixing spring from the back side of the con-
centric slave cylinder.
6. Remove the O–ring and the concentric slave cylin-
der.

6A – 2IPOWER STEERING SYSTEM
DAEWOO V–121 BL4
DIAGNOSIS
POWER STEERING SYSTEM
PRESSURE TEST
Tools Required
KM–354–B Pressure Test Gauge Kit
Check the fluid pressure as follows to determine whether
the trouble is in the pump or the gear unit.
Test Procedure
1. Check the power steering fluid level and the power
steering pump belt tension. Refer to ”Checking and
Adding Fluid” in this section and Section 6B, Power
Steering Pump.
2. Disconnect the high pressure line at the pump. Use
a small container to catch any fluid.
3. Connect the hose of the pressure test gauge kit
KM–354–B to the power steering pressure hose
from the power steering pump.
4. Place the gear selector lever in PARK (automatic
transaxle–equipped vehicles) or NEUTRAL (manual
transaxle–equipped vehicles). Set the parking
brake.
5. Open the gauge valve fully.
6. Start the engine and let it idle.
7. Turn the steering wheel from lock to lock several
times to warm the fluid to operating temperature.
8. Increase the engine speed to 1,500 rpm.
Notice : The power steering pump could be damaged if
the valve is fully closed for more than 5 seconds.
9. Close the gauge valve fully, and read the pressure.
The pump pressure with the valve closed should be
between 8,330 kPa to 8,820 kPa (1,208 psi to
1,279 psi). With electronic variable orifice, the pres-
sure should be between 8,500 kPa to 8,960 kPa
(1,233 psi to 1,299 psi).
10. Immediately open the gauge valve fully.
11. Turn the steering wheel all the way to the left and
the right. If the pressure is within the specified lim-
its, the problem is not in the pump. Check the pow-
er steering gear for leaks.
POWER STEERING SYSTEM LEAK
TEST
General Procedure
Inspect the following:
S The fluid reservoir for overfill.
S Fluid for aeration and overflow.
S The hoses for loose connections.
S The torsion bar, stub shaft and adjuster seals for
leaks.
S The component sealing surfaces for damage.
Important : Verify the exact point of the leak. The point
from which the fluid is dripping is not necessarily the point
at which the system is leaking. When service is required,
clean the leak area upon disassembly, replace the leaking
seal, check the component sealing surfaces for damage
and reset the torque bolt to specifications, where required.
External Leak Check
The purpose of this procedure is to pinpoint the location of
the leak. In some cases, the leak can be easily located, but
seepage–type leaks may be harder to find. To locate seep-
age leaks, use the following method:
1. With the engine off, wipe dry the complete power
steering system.
2. Check the power steering fluid level in the pump’s
reservoir. Adjust the fluid level as necessary. Refer
to ”Checking and Adding Fluid” in this section.
Notice : Do not hold the steering wheel at a stop for any
length of time as this can damage the power steering
pump.
3. Start the engine. Turn the steering wheel counter-
clockwise and clockwise from stop to stop several
times.
4. Find the exact area of the leak and repair it.