Reverse DAEWOO LACETTI 2004 Service Service Manual

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 – 137
DAEWOO V–121 BL4
MAJOR COMPONENT ASSEMBLY
Tools Required
DW240–020 Brake/Clutch Spring Compressor
DW240–050 Overdrive Brake Adapter
DW240–060–01 Brake Spring Compressor Bolt/Nut
DW240–060–02 Brake Spring Compressor Plate
DW240–070 1st / Reverse Brake Adapter
DW240–100 Counter Drive Gear Installation Adapter
DW240–130 Differential Preload Adapter
DW260–031–01 Transaxle Housing Oil Seal Installer
DW260–031–02 Transaxle Case Oil Seal Installer
DW260–041 Planetary Ring Gear Nut Removal/Installa-
tion Socket
DW240–160 Transaxle Case Outer Tapered Roller Bear-
ing Race Adapter
DW240–140 Transaxle Housing Side Bearing Outer Race
Adapter
DW240–170 Adapter Handle
Assembly Procedure
1. Install 4 new O–rings to the 4 screw plugs.
2. Install the 4 screw plugs with the O–rings to the
transaxle rear cover.
Tighten
Tighten the screw plugs to 7.4 NSm (65 lb–in).
3. Install the 2 seal rings to the transaxle rear cover.
4. Using the vernier calipers, measure the free length
of the O/D brake piston return spring together with
the spring seat.
S Standard free length : 18.99 mm (0.7476 in.)

AISIN AUTOMATIC TRANSAXLE 5A2 – 143
DAEWOO V–121 BL4
If the preload of counter driven gear does not satisfy the
specification, select the adjuster shim from the table below
and remeasure the valve. Until the valve is within the spec-
ification, repeat the procedure.
Notice : When the preload is larger than the specification,
select a thinner adjuster shim. When the preload is smaller
than specification, select a thicker adjuster shim.
S Adjuster shim thickness: mm (in.)
Mark
ThicknessMarkThickness
11.70 (0.0669)G2.17 (0.0854)
21.75 (0.0689)H2.20 (0.0866)
31.80 (0.0709)K2.25 (0.0886)
41.85 (0.0728)L2.30 (0.0906)
51.90 (0.0748)M2.35 (0.0925)
61.93 (0.0760)N2.40 (0.0945)
71.96 (0.0772)P2.45 (0.0965)
A1.99 (0.0783)Q2.50 (0.0984)
B2.02 (0.0795)R2.55 (0.1004)
C2.05 (0.0807)S2.60 (0.1024)
D2.08 (0.0819)U2.65 (0.1043)
E2.11 (0.0831)W2.70(0.1063)
F2.14 (0.0843)––
30. Using the vernier calipers, measure the free length
of the 1st & reverse brake piston return spring to-
gether with spring seat.
S Standard free length: 18.053 mm (0.71075 in.)
31. Check to see if the sliding surface of the disc, plate
and flange of 1st & reverse brake are worn or burnt.
If necessary, replace them.
Notice : If the lining of the disc is peeling off or discolored,
or even if a part of the groove is defaced, replace all discs.
Notice : Before assembling new discs, soak them in ATF
for at least 15 minutes.

5A2 – 144IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
32. Coat 2 new O–rings with ATF, install them to the
1st & reverse piston.
33. Install the 1st & reverse brake piston to the trans-
axle case.
Notice : Be careful not to damage the O–rings of the 1st
& reverse brake piston.
34. Install the return spring to the transaxle case.
35. Install the 4 plates, 4 discs and flange.
S Install in order : P
D
P
D
P
D
P
D

F
(P= Plate, D= Disc, F= Flange)

AISIN AUTOMATIC TRANSAXLE 5A2 – 145
DAEWOO V–121 BL4
36. Using 1st & reverse brake adapter DW240–070 and
brake spring compressor bolt/nut DW240–060–01,
install the snap ring.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
37. Using a dial indicator, measure the 1st & reverse
brake piston stroke while applying and releasing
392–785 kPa (57–114 psi) of compressed air.
Notice : If the piston stroke is non–standard, inspect the
discs, plates and flange. Piston stroke 0.6
1.3 mm (0.024

0.051 in.)
38. Using counter drive gear installation adapter
DW240–100, brake spring compressor bolt/nut
DW240–060–01 and brake spring compressor plate
DW240–060–02, install the counter drive gear.
Notice : Be careful not to apply excessive force to the
transaxle case.
39. Coat a new oil seal with ATF.
40. Install the oil seal to the transaxle case.
S Oil seal in depth:
A: 1 ± 0.25 mm (0.39 ± 0.0098 in.)

5A2 – 154IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
77. Install the forward clutch hub to the transaxle case.
78. Coat the thrust bearing race with petroleum jelly
and install it onto the forward clutch hub.
S Race:
Inner diameter: 19.3 mm (1.760 in.)
Outer diameter: 30.6 mm (1.205 in.)
79. Install the thrust bearing race and thrust needle roll-
er bearing to the forward & reverse clutch assem-
bly.
S Race and bearing diameter: mm(in.)
Inner diameterOuter diameter
Race18.1 (0.713)28.2 (1.110)
Bearing18.1 (0.713)29.6 (1.165)
80. Install the forward & reverse clutch assembly to the
transaxle case.

5A2 – 156IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
86. As shown in the illustration, place a straight edge
on the O/D brake piston and measure the distance
between the transaxle rear cover and straight edge
using vernier calipers. (Dimension B).
87. Calculate the piston stroke value using the following
formula. Select a flange which satisfies the piston
stroke value and install it.
Piston stroke = Dimension A
Dimension B
Piston stroke : 0.65
1.05 mm (0.0256
0.0413
in.)
S Flange thickness : mm (in.)
Piston stroke
value
ThicknessMark
0.738 ~ 0.949
(0.02905 ~
0.03736)3.0
(0.118)0
0.950 ~ 1.149
(0.03740 ~
0.04524)3.2
(0.126)1
1.150 ~ 1.349
(0.04528 ~
0.05311)3.4
(0.134)2
1.350 ~ 1.549
(0.05315 ~
0.06098)3.6
(0.142)3
1.550 ~ 1.702
(0.06102 ~
0.06701)3.8
(0.150)0
88. Install new 4 apply gaskets to the transaxle rear
cover.
89. Coat the thrust neddle roller bearing with petroleum
jelly and install it onto the forward & reverse clutch
assembly.
S Bearig:
Inner diameter: 43.2 mm (1.701 in.)
Outer diameter: 62.0 mm (2.441 in.)
90. Remove any packing material and be careful not to
get oil on the contacting surfaces of the transaxle
rear cover or transaxle case.

AISIN AUTOMATIC TRANSAXLE 5A2 – 183
DAEWOO V–121 BL4
FORWARD AND REVERSE CLUTCH
1. Seal Ring
2. Flange
3. Disc
4. Plate
5. Flange
6. Snap Ring
7. Flange
8. Disc
9. Plate10. Snap Ring
11. Clutch Balancer
12. Forward Clutch Retrun Spring
13. Forward Clutch Piston
14. O–Ring
15. Forward Clutch Drum
16. O–Ring
17. Intermediate Shaft Sub–assembly

5A2 – 184IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Tools Required
DW240–020 Brake/Clutch Spring Compressor
DW240–030 Forward Clutch Adapter
DW240–120 Measuring Terminal
Disassembly Procedure
WARNING : USE CAUTION WHEN CHECKING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
1. Install the forward and reverse clutch and thrust
needle roller bearing on the transaxle rear cover.
2. Using a dial indicator, measure the reverse clutch
pack clearance while applying and releasing 392
kPa (57 psi) of compressed air.
S Pack clearance: 0.40
1.00 mm (0.0157

0.0394 in.)
S If the stroke is non–standard, inspect the discs,
plates and flange.
WARNING : USE CAUTION WHEN CHECKING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
3. Install the forward and reverse clutch and thrust
needle roller bearing on the transaxle rear cover.
4. Using a dial indicator and measuring terminal
DW240–120, measure the forward clutch pack
clearance while applying and releasing 392 kPa (57
psi). of compressed air.
S The forward and reverse clutch will come out as
you apply the compressed air. Therefore, while
the checking is being done, press on the input
shaft of the forward and reverse clutch using
stamping machine or alike so that the pressure
is not applied on the forward and reverse clutch.
S Pack clearance: 1.1–1.5 mm (0.043
0.059 in.)
If the stroke is non–standard, inspect the discs,
plates and flange.
5. Using a screwdriver, remove the reverse clutch
snap ring.