key DAEWOO LACETTI 2004 Service Workshop Manual

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 223
DAEWOO V–121 BL4
6. Remove cylinder with piston C.
7. Separate between piston C and cylinder C.
8. Take snap ring out of brake C.
9. Remove the disc set C.
Installation Notice
S Transaxle has two lined clutch discs and one
steel clutch disc. The lined discs must be
installed in such a way that the lining faces the
steel disc.
S Insert the fitting keys into the appropriate
grooves.

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

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)

AISIN AUTOMATIC TRANSAXLE 5A2 – 205
DAEWOO V–121 BL4
Lower Valve Body
1. Key
2. Spring
3. 4–3 Shift Timing Valve
4. Key
5. Plug
6. 2–3 Shift Valve
7. Spring
8. Key
9. Plug
10. 1–2 Shift Valve
11. Spring
12. Key
13. Sleeve
14. Plunger15. Spring
16. Primary Regulator Valve
17. Key
18. Sleeve
19. Plunger
20. Spring
21. Lock–up Relay Valve
22. Key
23. Spring
24. Solenoid Modulator Valve
25. Solenoid Oil Strainer
26. Lower Modulator Valve
27. Spring
28. Key

AISIN AUTOMATIC TRANSAXLE 5A2 – 207
DAEWOO V–121 BL4
Lower Valve Body Key
MarkRetainerHeight/Width/Thickness mm (in.)
A4–3 shift timing valve No.136.0 (1.417) / 5.0 (0.197) / 3.2 (0.126)
BLow modulator valve24.0 (0.945) / 5.0 (0.197) / 3.2 (0.126)
C2–3 shift valve10.0 (0.394) / 5.0 (0.197) / 3.2 (0.126)
D1–2 shift valve10.0 (0.394) / 5.0 (0.197) / 3.2 (0.126)
EPrimary regulator valve9.8 (0.386) / 5.2 (0.205) / 3.2 (0.126)
FLock up relay valve16.0 (0.630) / 5.0 (0.197) / 3.2 (0.126)
GSolenoid modulator valve24.0 (0.945) / 5.0 (0.197) / 3.2 (0.126)

5B – 10IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
1. Roller Bearing
2. Transaxle Main Shaft
3. Washer
4. Washer Retaining Ring
5. 4th Speed Gear
6. Needle Cage
7. Synchronizer Ring
8. Shift Sleeve
9. Synchronizer Key
10. 3rd & 4th Synchronizer Spring
11. Washer
12. Circlip
13. 3rd Speed Gear
14. Washer
15. Washer Retaining Ring
16. 2nd Speed Gear
17. Needle Cage
18. Inside Synchronizer Ring
19. Intermediate Ring
20. Outside Synchronizer Ring
21. Sliding Gear
22. 1st & 2nd Synchronizer Key
23. 1st & 2nd Synchronizer Spring
24. Washer
25. Circlip
26. 1st Speed Gear
27. Needle Cage28. Needle Cage
29. Main Shaft Disc
30. Retaining Ring
31. Groove Ball Bearing
32. Washer
33. Retaining Ring
34. 5th Speed Gear
35. Needle Cage
36. Synchronizer Ring
37. 5th Shift Sleeve
38. 5th Synchronizer Spring
39. 5th Synchronizer Key
40. Retaining Ring
41. Needle Sleeve
42. Input Drive Shift
43. Input Shaft Cluster Gear
44. Bolt
45. Retaining Ring
46. Cluster Bearing Ring
47. Groove Ball Bearing
48. Cluster 5th Speed Gear
49. Retaining Ring
50. Washer
51. Reverse Idler Gear
52. Reverse Idler Gear Shaft
53. Ball

5B – 38IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
6. Remove the keys from the first–second synchroniz-
er gear.
7. Remove the barrel–type first–gear needle bearing.
8. Remove the snap ring and the washer.
9. Remove the first–second synchronizer gear from
the mainshaft.

5B – 40IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
14. Remove the third gear and the synchronizer block-
ing ring.
15. Separate the synchronizer blocking ring from the
third gear.
16. Remove the third–gear needle bearing from the
mainshaft.
17. Remove the synchronizer sleeve containing the
keys and the spring.

5B – 44IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
7. Install the synchronizer sleeve containing the keys
and the spring.
8. Install the third–gear needle bearing.
9. Attach the synchronizer blocking ring to the third
gear.
10. Install the third–gear assembly.

5B – 46IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
15. Install the first–second synchronizer gear.
16. Install the washer and the snap ring.
17. Install the first–gear needle bearing.
18. Install the keys onto the first–second synchronizer
gear.