Transaxle DAEWOO LACETTI 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 209
DAEWOO V–121 BL4
Tools Required
DW260–031–01 Transaxle Housing Oil Seal Installer
DW260–031–02 Transaxle Case Oil Seal Installer
DW240–150 Transaxle Case Side Bearing Outer Race
Adapter
DW240–140 Transaxle Housing Side Bearing Outer Race
Adapter
DW240–170 Adapter Handle
Disassembly Procedure
1. Place the matchmarks on the ring gear and differ-
ential case.
2. Remove the 8 bolts.
3. Using a plastic hammer, tap on the ring gear to re-
move it from the case.
4. Using a suitable puller, remove the tapered roller
bearing of transaxle housing side.

5A2 – 210IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
5. Using a suitable puller, remove the tapered roller
bearing of transaxle case side.
6. Using a pin punch and hammer, drive out the pin
from the ring gear side.
7. Remove the differential pinion shaft from the case.
8. Remove the 2 differential pinion gears, 2 differential
side gears, 2 differential pinion thrust washers and
2 differential side gear thrust washers.

AISIN AUTOMATIC TRANSAXLE 5A2 – 211
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9. 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.
10. Using a suitable puller, remove the side bearing
outer race of transaxle housing.
11. Using a driver, remove the oil seal of transaxle
case.
Notice : Be careful not to damage the transaxle case
when removing the oil seal using a driver.
12. Using transaxle case side bearing outer race adapt-
er DW240–150 and adapter handle DW240–170,
remove the transaxle case side bearing outer race
and shim.

5A2 – 212IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Assembly Procedure
1. Using transaxle housing side bearing outer race
adapter DW240–140 and adapter handle
DW240–170, install a new side bearing outer race
into the transaxle housing.
2. Install the shim to the transaxle case.
Notice : First install a shim of the same thickness as be-
fore.
3. Install a new side bearing outer race into the trans-
axle case.
4. Coat the thrust washers, side gears, pinion gears
and pinion thrust washers with ATF.
5. Install the 2 differential side gear thrust washers to
2 differential side gears.
6. Install the 2 side gears with 2 thrust washers, 2 pin-
ion gears and 2 pinion thrust washers into the dif-
ferential case.
7. Coat the pinion shaft with ATF.

AISIN AUTOMATIC TRANSAXLE 5A2 – 213
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8. Install the pinion shaft so as to align the lock pin
holes on the pinion shaft and differential case.
9. Measure the side gear backlash while holding 1
pinion gear toward the case.
S Standard backlash:
0.05
0.20 mm (0.0020–0.0079 in.)
If the backlash is out of specification, install the
correct thrust washer to the side gear.
10. Referring to the table below, select thrust washers
which will ensure that the backlash is within the
specification.
Try to select washers of the same size for both
sides.
Thrust washer thickness : mm (in.)
Thickness
Thickness
0.95 (0.0374)1.10 (0.0433)
1.00 (0.0394)1.15 (0.0453)
1.05 (0.0413)1.20 (0.0472)
If the backlash is not within the specification,
install a thrust washer of a different thickness.
11. Using a hammer and punch, drive in the pin
through the case and hole in the pinion shaft.

5A2 – 214IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
12. Using a hammer and chisel, stake the differential
case.
13. Using a press, install the tapered roller bearing into
the differential case.
14. Using a press, install the tapered roller bearing into
the differential case.
15. Remove any formed in place gasket (FIPG) materi-
al and be careful not to get oil on the contacting
surfaces of the transaxle housing or transaxle case.
16. Install the differential to the transaxle case.

AISIN AUTOMATIC TRANSAXLE 5A2 – 215
DAEWOO V–121 BL4
17. Install the transaxle housing and 16 bolts of the
transaxle housing temporarily.
18. Tighten 8 or 9 bolts out of 16 bolts of the transaxle
housing completely.
Tighten
Tighten the bolts to 29 NSm (22 lb–ft).
19. Using differential preload adapter DW240–130, turn
the differential gear assembly right and left 2 or 3
times to allow the bearing settle.
20. Using differential preload adapter DW240–130 and
small torque wrench, measure the preload of the
differential gear.
S Preload:
New bearing: 0.78–1.37 N.m (6.9–12.2 lb –in)
Used bearing : 0.39–0.69 N.m (3.5
6.1 lb–in)
If the preload is not within the specification, re-
move the differential from the transaxle case.
Re–select the transaxle case side adjusting
shim according to the following table.
S Adjusting shim thickness :mm (in.)
Mark
ThicknessMarkThickness
A1.80 (0.0709)N2.26 (0.0890)
B1.85 (0.0728)P2.29 (0.0902)
C1.90 (0.0748)Q2.32 (0.0913)
D1.95 (0.0768)R2.35 (0.0925)
E2.00 (0.0787)S2.40 (0.0945)
F2.05 (0.0807)T2.45 (0.0965)
G2.08 (0.0819)U2.50 (0.0984)
H2.11 (0.0831)V2.55 (0.1004)
J2.14 (0.0843)W2.60 (0.1024)
K2.17 (0.0854)X2.65 (0.1043)
L2.20 (0.0866)Y2.70 (0.01063)
M2.23 (0.0878)

5A2 – 216IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
21. Using a plastic hammer, remove the 16 bolts and
transaxle housing.
22. Remove the differential gear from the transaxle
case.
23. Clean the contact surface of the differential case.
24. Heat the ring gear in water and boil for 10 minutes.
25. Carefully remove the ring gear from the water.
26. After the moisture on the ring gear has completely
evaporated, quickly install the ring gear to the differ-
ential case.
27. Install the 8 bolts.
Tighten
Tighten the bolts to 102 NSm (75 lb–ft).

AISIN AUTOMATIC TRANSAXLE 5A2 – 217
DAEWOO V–121 BL4
28. Using transaxle housing oil seal installer
DW260–031–01 and a hammer, drive in a new
transaxle housing oil seal .
S Oil seal in depth : 3.1 mm (0.122 in.)
29. Using transaxle case oil seal installer
DW260–031–02, drive in a new transaxle case oil
seal.
S Oil seal in depth : 4.3 mm (0.169 in.)

5A2 – 218IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
TRANSAXLE DESCRIPTION
The new automatic transmission is an electronically con-
trolled 4–speed automatic transmission with Lock–up
mechanism.
The transmission is mainly composed of the torque con-
verter with lock up clutch, newly developed 4–speed plan-
etary gear unit, the hydraulic control system and the elec-
tric control system.
ELECTRONICAL COMPONENTS
Transmission Control Module (TCM)
The TCM primarily controls shift points and lockup en-
gagement. It is located on the driver side under the instru-
ment panel.
The transmission is controlled by an electronic shift sys-
tem. The Transmission Control Module (TCM) processes
input signals. From the information received, the TCM
controls the transmission hydraulic system.
The electronic shift system consists of the following :
S Transmission control module (TCM)
S Shift solenoids (SS1 and SS2)
S Pressure control solenoid (PCS)
S Lockup solenoid
S Input shaft speed (ISS) sensor
S Output shaft speed (OSS) sensor
S Transmission Fluid Temperature (TFT) sensor
S Transmission Range (TR) Switch
Transmission Range (TR) Switch
Transmission Range (TR) Switch transmits the informa-
tion which range includes shift lever of A/T to Starter and
TCM.
S It is possible for TR switch to start an engine in only
”P” and ”N”. (Prevention of reckless driving)
S TR switch makes backup lamp turn on when re-
versing.
S It is used for TR switch to shift control.
TR switch transmits the information by combination of
starter and reverse circuit to vehicle side directly without
TCM.
Shift Solenoid No 1,2 (SS1, SS2)
2 shift solenoids are installed directly in the valve body.
The solenoids operate of ON and OFF by the control sig-
nal from TCM. Combinations of 2 solenoids, SS1 and SS2
changes gear ranges.