section 5 DAEWOO LACETTI 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 101
DAEWOO V–121 BL4
Installation Procedure
1. Install the shift control lever assembly and mount-
ing bolts and nuts.
Tighten
Tighten the shift control lever assembly mounting
bolts and nuts to 8 NSm (71 Ib–in).
2. Connect the control cable to the shift control lever
assembly.
3. Tighten the control cable adjusting nut.
Tighten
Tighten the control cable adjusting nut to 8 NSm (71
Ib–in).
4. Connect the harness connector.
5. Adjust the control cable. Refer to ”Control Cable
Adjustment” in this section.
6. Install the floor console. Refer to Section 9G, Interi-
or Trim.
7. Connect the negative battery cable.
TRANSMISSION RANGE (TR)
SWITCH
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the Transmission Range (TR) switch
electrical connector from the wiring harness.

AISIN AUTOMATIC TRANSAXLE 5A2 – 103
DAEWOO V–121 BL4
6. Aligh the groove with the neutral basic line, then
install the 2 bolts.
Tighten
Tighten the 2 bolts to 5.4 NSm (48 Ib–in).
7. Using a screw driver, stake the nut with the lock
washer.
8. Install the control lever, washer and nut.
Tighten
Tighten the nut to 12 NSm (106 Ib–in).
9. Connect the control cable to TR switch.
10. Connect the TR switch electrical connector.
11. Adjust the control cable. Refer to ”Control Cable
Adjustment” in this section.
12. Install the control cable adjusting nut.
Tighten
Tighten the control cable adjusting nut to 8 NSm (71
Ib–in).
13. Connect the negative battery cable.

5A2 – 104IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
SHIFT CONTROL CABLE
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the floor console. Refer to Section 9G,
Interior Trim.
3. Remove the cable adjusting nut.
4. Disconnect the shift control cable from the shift
control lever assembly.
5. Remove the shift control cable retaining E–ring.
6. Disconnect the shift control cable from the TR
switch.
7. Remove the E–ring from the shift control cable
bracket and disconnect the shift control cable.
8. Disconnect the shift control cable from the shift
control cable fastener.
9. Remove the shift control cable from the vehicle.
Installation Procedure
1. Install the shift control cable to the vehicle.
2. Connect the shift control cable to the shift control
cable fastener.
3. Install the E–ring to the shift control cable bracket
and connect the shift control cable.

AISIN AUTOMATIC TRANSAXLE 5A2 – 105
DAEWOO V–121 BL4
4. Connect the shift control cable to the TR switch.
5. Install the shift control cable retaining E–ring.
6. Connect the shift control cable to the shift control
lever assembly.
7. Install the cable adjusting nut.
Tighten
Tighten the cable adjusting nut to 8 NSm (71 Ib–in).
8. Install the trim panel to the floor console. Refer to
Section 9G, Interior Trim.
9. Connect the negative battery cable.
SHIFT SELECT COVER
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the floor console. Refer to Section 9G,
Interior Trim.
3. Remove the shift select lever knob.
4. Disconnect the connectors.
5. Remove the shift select cover from the shift select
housing.

5A2 – 106IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Connect the connectors to the shift select cover.
2. Install the shift select cover to the housing.
3. Install the shift select lever knob.
4. Install the floor console. Refer to Section 9G, Interi-
or Trim.
5. Connect the negative battery cable.
INPUT SHAFT SPEED (ISS) SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the input shaft speed (ISS) sensor elec-
trical connector.
3. Remove the ISS sensor retaining bolt.
4. Remove the ISS sensor from the transaxle.

AISIN AUTOMATIC TRANSAXLE 5A2 – 111
DAEWOO V–121 BL4
Installation Procedure
1. Install the fluid cooler rear outlet pipe fitting nut.
Tighten
Tighten the fluid cooler rear outlet pipe fitting nut to 35
NSm (26 Ib–ft).
2. Install the fluid cooler rear outlet pipe clip bolt.
Tighten
Tighten the fluid cooler rear outlet pipe clip bolt to 9
NSm (80 Ib–in).
3. Install the front outlet pipe union bolt into the radia-
tor.
Tighten
Tighten the front outlet pipe union bolt to 35 NSm (26
Ib–ft).
4. Install the clip into the hose.
5. Fill the transaxle with the fluid.
TRANSAXLE ASSEMBLY
Tools Required
DW110–060 Engine Support Fixture
DW260–012 Transaxle Support Fixture (81–40 LE)
Removal Procedure
1. Remove the battery and battery tray. Refer to Sec-
tion 1E, Engine Electrical.
2. Drain the transaxle fluid. Refer to ”Fluid Drain Pro-
cedure” in this section.
3. Remove the left and right drive axle assemblies.
Refer to Section 3A, Automatic Transaxle Drive
Axle.
4. Disconnect the fluid cooler inlet and outlet pipes
and hoses from the transaxle. Refer to ”Fluid Cool-
er Inlet or Outlet Pipe and Hoses” in this section.
5. Disconnect the shift control cable from the trans-
axle. Refer to ”Shift Control Cable” in this section.
6. Install engine support fixture DW110–060 to sup-
port the engine.

AISIN AUTOMATIC TRANSAXLE 5A2 – 115
DAEWOO V–121 BL4
5. Install the rear mounting bracket bolts and the
bracket.
Tighten
Tighten the rear mounting bracket bolts to 60 NSm (44
Ib–ft).
6. Install the damping block connection nut and bolt.
Tighten
Tighten the damping block connection nut and bolt to
80 NSm (59 Ib–ft).
7. Install the torque converter bolts.
Tighten
Tighten the torque converter bolts to 45 NSm (33 Ib–
ft).
8. Install the service hall cover.
9. Connect the transaxle electrical connector.
10. Connect the TR switch electrical connector.
11. Connect the OSS sensor electrical connector.
12. Connect the ISS sensor electrical connector.
13. Remove engine support fixture DW110–060.
14. Connect the shift control cable into the transaxle.
Refer to ”Shift Control Cable” in this section.

5A2 – 116IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
15. Connect the fluid cooler inlet and outlet pipe and
hose into the transaxle. Refer to ”Fluid Cooler Inlet
or Outlet Pipe and Hoses” in this section.
16. Install the left and right drive axle assemblies. Refer
to Section 3A, Automatic Transaxle Drive Axle.
17. Install the battery and battery tray. Refer to Section
1E, Engine Electrical.
18. Fill the transaxle with fluid. Refer to ”Fluid Drain
Procedure” in this section.
19. Check the fluid level. Refer to ”Transaxle Fluid Lev-
el Checking Procedure” in this section.

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.

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. . . . . . . . . . . . . .