Transaxle DAEWOO LACETTI 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 55
DAEWOO V–121 BL4
8. Install the differential assembly into the transaxle
case.
9. Install the right–side bearing retainer and the right-
side bearing retainer bolts.
Tighten
Tighten the right–side bearing retainer bolts to 25
NSm (18 lb–ft).
10. Install the bearing–adjusting ring.
11. Tighten the bearing–adjusting ring using the remov-
er/ installer KM–520.
Tighten
Tighten the bearing adjusting ring until there is no end
play with the differential.
Adjust the preload on the differential bearings.
Used Bearings:
1 NSm (9 lb–in) required to rotate the differential one
revolution per second.
New Bearings:
2 NSm (18 lb–in) required to rotate the differential one
revolution per second.
Tighten or loosen the bearing ring adjuster to get the
required preload on the bearings.
12. Install the bearing–adjusting ring–retainer plate and
the bearing–adjusting ring–retainer plate bolt.
Tighten
Tighten the bearing–adjusting ring–retainer plate bolt
to 5 NSm (44 lb–in).

5B – 56IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
13. Install the differential cover gasket, the differential
cover, and the differential cover bolts.
Tighten
Tighten the differential cover bolts to 40 NSm (30 lb–
ft).
MAJOR COMPONENT ASSEMBLY
Tools Required
J–36633 Snap Ring Retainer
KM–334 Installer Sleeve
KM–552 Fixture
KM–554 Installer
KM–113–2 Base
Assembly Procedure
1. Join the mainshaft and the input shaft.
2. Compress the snap ring at the base of the main-
shaft and hold with the snap ring retainer J–36633.
3. Hold the snap ring at the base of the input drive-
shaft with the snap ring pliers.
4. Install the mainshaft/input shaft assembly onto the
bearing plate.
5. Release the mainshaft snap ring and the input shaft
snap ring.
6. Position the first–second gearshift fork.
7. Install the fifth gearshift lever into the bearing plate.

FIVE–SPEED MANUAL TRANSAXLE 5B – 57
DAEWOO V–121 BL4
8. Install the third–fourth gearshift rod/fork holding pin.
9. Install the support bracket onto the bearing plate.
10. Install the first–second gearshift rod/fork onto the
bearing plate.
11. Install the first–second gearshift fork holding pin.

5B – 58IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
12. Install the support bracket bolts.
Tighten
Tighten the support bracket bolts to 7 NSm (62 lb–in).
13. Install the reverse gearshift rod/fork onto the bear-
ing plate.
14. Install the reverse gearshift rod/fork holding pin.
15. Install the rod lock pin and spring into the small plug
hole.

FIVE–SPEED MANUAL TRANSAXLE 5B – 59
DAEWOO V–121 BL4
16. Install the fourth–gearshift rod plugs.
17. Install the bolts and the fifth–gearshift connector
onto the bearing plate, using the pawl.
Tighten
Tighten the fifth–gearshift connector bolts to 7 NSm
(62 lb–in).
18. Install the input drive fifth gear using the installer
KM–554 and the installer sleeve KM–334.
19. Install the snap rings securing the fifth–drive gear.

5B – 60IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
20. Install the thrust washers, the retaining ring, and
the needle bearing into the mainshaft–driven fifth–
gear assembly.
21. Install the brass synchronizer ring onto the main-
shaft– driven fifth–gear assembly.
22. Install the mainshaft–driven fifth–gear assembly.
23. Install the fifth–drive gear synchronizer gear and
the synchronizer sleeve using installer KM–554.
24. Install the snap ring holding the fifth speed–driven
assembly.

FIVE–SPEED MANUAL TRANSAXLE 5B – 61
DAEWOO V–121 BL4
25. Install the bolts and the fifth–gear fork onto the
bearing plate.
Tighten
Tighten the fifth–gear fork bolts to 22 NSm (16 lb–ft).
26. Remove the bearing plate from the fixture KM–552.
27. Shift the transaxle into second gear.
28. Install the bearing plate, with the shafts attached,
into the case.
29. Install the bearing plate bolts.
Tighten
Tighten the bearing plate bolts to 22 NSm (16 lb–ft).
30. Install the speedometer–driven gear and the
speedometer–housing retaining bolt into the trans-
axle housing.
Tighten
Tighten the speedometer housing retaining bolt to 4
NSm (35 lb–in).

5B – 62IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
31. Bolt the gearshift lever cover to the fixture KM–552.
32. Position the fixture into the base KM–113–2.
33. Install the gearshift rod, the shift finger lever, and
the gearshift lever pin.
34. Install the snap ring, the bushing, the spring, and
the intermediate lever.
35. Remove the gearshift lever cover from the base
KM–113–2 and the fixture KM–552.
36. Shift the transaxle into NEUTRAL.
37. Install the gearshift lever cover and the gearshift
lever cover bolts.
Tighten
Tighten the gearshift lever cover bolts to 22 NSm (16
lb–ft).
38. Install the transaxle cover and the transaxle cover
bolts.
Tighten
Tighten the transaxle cover bolts to 18 NSm (13 lb–ft).
39. Install the transaxle into the vehicle. Refer to
”Transaxle Assembly” in this section.

FIVE–SPEED MANUAL TRANSAXLE 5B – 63
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FIVE–SPEED MANUAL TRANSAXLE
This five–speed transaxle assembly is a transmission of
constant–mesh design.
Combined in the assembly are:
S All forward gears.
S The reverse gear.
S The differential output.
The basic components of the five–speed transaxle as-
sembly units are the:
S Transaxle case.
S Input shaft.
S Input shaft gears.S Output shaft.
S Output shaft gears.
S Ring gear and differential assembly.
Forward Gear
Shifting to a forward gear is accomplished through a com-
bination of synchronizers with blocker rings controlled by
sliding shift forks.
Reverse Gear
Reverse gear is not synchronized and uses a sliding idler
gear arrangement.
Differential Assembly
The differential is a conventional arrangement of gears
that is supported by tapered roller bearings. The final out-
put gear turns the ring gear and differential assembly
which turns the drive axle shafts.

5C – 8ICLUTCH
DAEWOO V–121 BL4
CLUTCH RELEASE POINT
ADJUSTMENT
Adjustment Procedure
1. Apply the parking brake.
2. Run the engine at idle speed.
3. While you move the shift lever into the reverse
position, depress the clutch pedal slowly and mea-
sure the distance between the point when gear
noise is not heard and the point the clutch pedal is
completely depressed. The distance should be 30
to 40 mm (1.2 to 1.6 inches).
4. If the distance is not within the specified value,
check the following:
S Clutch pedal height
S Clutch pedal play
S Air in the system
S Clutch cover and disc pressure plate
AIR BLEEDING
Bleed the hydraulic system to remove the air which en-
tered when the pipes were disconnected for repairs. The
clutch/brake fluid in the clutch/brake reservoir must be
maintained at the MIN level or higher during air bleeding.
1. Attach a vinyl hose to the bleeder plug. Place the
other end of the vinyl tube in a glass container half–
filled with brake fluid.
2. Slowly pump the clutch pedal several times.
3. While you press the clutch pedal, loosen the bleed-
er screw until the fluid starts to run out. Close the
bleeder screw.
4. Repeat Step 3 until there are no air bubbles in the
fluid.
5. Fill the reservoir with brake fluid up to the proper
level.
PRESSURE PLATE AND CLUTCH
DISC
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the transaxle from the vehicle. Refer to
Section 5B, Five–Speed Manual Transaxle.
3. Remove the pressure plate bolts and the pressure
plate.
Important : Support the pressure plate when you remove
the last bolt.