Reverse DAEWOO LACETTI 2004 Service Workshop Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 185
DAEWOO V–121 BL4
6. Remove the 2 flanges, 2 discs and plate from the
reverse clutch drum.
7. Using a screwdriver, remove the snap ring.
8. Remove the flange, 3 discs and 3 plates from the
forward clutch drum.
9. Using brake/clutch spring compressor DW240–020
and forward clutch adapter DW240–030, compress
the spring.
10. Using a snap ring expander, remove the snap ring.
Notice : Stop the press when the clutch balancer is low-
ered to the place 1–2 mm (0.039–0.078 in.) from the snap
ring groove, preventing the clutch balancer from being de-
formed.
Notice : Do not expand the snap ring excessively.

5A2 – 186IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
11. Remove the clutch balancer and forward clutch re-
turn spring.
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
12. Install the forward and reverse multiple disc clutch
on the transaxle rear cover.
13. Apply 392 kPa (57 psi) of compressed air to the
transaxle rear cover to remove the forward clutch
piston.
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.
S When the piston can not be removed as it is
slanted, either blow the air again with the pro-
truding side pushed or remove the piston using
a needle nose pliers with vinyl tape on the tip.
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
14. Apply 392 kPa (57 psi) of compressed air to the
transaxle rear cover to remove the forward clutch
drum.
Notice : Blowing off the air may cause the drum’s jump–
out. When removing the drum, hold it with your hand using
a waste cloth.
Notice : Take care not to splash ATF when air–blowing.
S When the drum can not be removed as it is
slanted, either blow the air again with the pro-
truding side pushed or remove the drum using a
needle nose pliers with vinyl tape on the tip.

5A2 – 190IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
11. Install the plate, 2 discs and 2 flanges.
S Install in order: F
D
P
D – F
(P = Plate, D = Disc, F = Flange)
12. Using a screwdriver, install the snap ring.
13. Check that the end gap of the snap ring is not
aligned with one of the cutouts.
WARNING : USE CAUTION WHEN CHECKING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
14. Install the forward and reverse clutch and thrust
needle roller bearing on the transaxle rear cover.
15. 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.) If the pack clearance is less than the
limit of pack clearance, parts may have been
assembled incorrectly, so check and reassemble
again.
If the pack clearance is non–standard, select
another flange.
There are 4 flanges in different thickness.
S Flange Thickness: mm (in.)
No
ThicknessNoThickness
13.0 (0.118)33.4 (0.134)
23.2 (0.126)43.6 (0.142)

AISIN AUTOMATIC TRANSAXLE 5A2 – 191
DAEWOO V–121 BL4
16. Install the forward and reverse clutch and thrust
needle roller bearing on the transaxle rear cover.
17. 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 pack clearance is less than the limit of
pack clearance, parts may have been as-
sembled incorrectly, so check and reassemble
again.
If the pack clearance is non–standard, select
another flange.
There are 4 flanges in different thickness.
S Flange Thickness: mm (in.)
No
ThicknessNoThickness
13.0 (0.118)33.4 (0.134)
23.2 (0.126)43.6 (0.142)

AISIN AUTOMATIC TRANSAXLE 5A2 – 201
DAEWOO V–121 BL4
Upper Valve Body
1. Sleeve
2. Key
3. Spring
4. Plunger
5. Lock–up Control Valve
6. Plug
7. Key
8. Secondary Regulator Valve
9. Spring
10. No.2 Check Valve
11. Key
12. Ball
13. No.1 Check Valve
14. Reverse Control Valve
15. Spring
16. Key17. Plug
18. Spring
19. 3–4 Shift Valve
20. Spring
21. O–ring
22. Reverse Clutch Accumulator Piston
23. O–ring
24. Plunger
25. 3–4 Shift Timing Valve
26. Spring
27. O–ring
28. 2nd Brake Accumulator Piston
29. O–ring
30. Spring
31. Upper Valve Body Cover

5A2 – 202IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Upper Valve Body Spring
S During reassembly, please refer to the spring specifications below to help you do discriminate between the differ-
ent springs.
MarkName (Color)Free length/Outer diameter mm
(in.)Total number of
coils
A3–4 shift timing valve (Pink)28.41 (1.1185) / 6.4 (0.252)10.49
B2nd brake accumulator piston,(None)
Inner45.90 (1.8071) / 10.5 (0.413)16.9
C2nd brake accumulator piston,(White)
Outer69.00 (2.7165) / 16.0 (0.630)15.1
DReverse clutch accumulator piston
(None)65.40(2.5748) / 17.0 (0.669)13.7
E3–4 shift valve (Red)25.50 (1.0039) / 9.73 (0.3831)7.75
FSecondary regulator valve (White)34.56 (1.3606) / 8.8 (0.346)12.27
GReverse control valve (None)25.58 (1.0071) / 8.64 (0.3402)8.75
HLock up control valve (Yellow)20.87 (0.8217) / 5.55 (0.2185)11.15

AISIN AUTOMATIC TRANSAXLE 5A2 – 203
DAEWOO V–121 BL4
Upper Valve Body Key
MarkRetainerHeight/Width/Thickness mm (in.)
ACheck valve11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)
BSecondary regulator valve16.0 (0.630) / 5.0 (0.197) / 3.2 (0.126)
CLock up control valve16.0 (0.630) / 5.0 (0.197) / 3.2 (0.126)
DReverse control valve11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)

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.

5A2 – 222IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
AUTOMATIC TRANSAXLE SYSTEM
Function of Components
ComponentFunction
C1Forward ClutchConnects input shaft and front sun gear.
C2Direct ClutchConnects input shaft and planetary carrier.
C3Reverse ClutchConnects input shaft and rear sun gear.
B1O/D & 2nd BrakePrevents rear planetary sun gear from turning either clockwise
or counterclockwise.
B22nd BrakePrevents outer race of F1 from turning either clockwise or coun-
terclockwise, thus preventing the rear sun gear turning conter-
clockwise.
B31st & Reverse BrakePrevents planetary carrier from turning either clockwise or
counterclockwise.
F1No.1 One–way ClutchWhen B2 is operating, this clutch prevents rear sun gear from
counterclockwise.
F2No.2 One–way ClutchPrevents planetary carrier from turning counterclockwise.
Planetary GearThese gears change the route through which driving froce is
transmitted, in accordance with the operation of each clutch
and brake, in order to increase or reduce the input and output
speed.

AISIN AUTOMATIC TRANSAXLE 5A2 – 223
DAEWOO V–121 BL4
Operations of Clutches and Brakes
Clutch & BrakeOperation
C1Forward ClutchConnects intermediate shaft and front sun gear.
C2Direct ClutchConnects input shaft and Planetary carrier.
C3Reverse ClutchConnects intermediate shaft and rear sun gear.
B1O/D & 2nd BrakeLock rear sun gear
B22nd BrakeLock rear sun gear
B31st & Reverse BrakeLock Planetary carrier
F11way Clutch No.1Lock counterclockwise rotation of rear sun gear, when B2 op-
erations
F21way Clutch No.2Lock counterclockwise rotation of planetary carrier