lock DAEWOO LACETTI 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 117
DAEWOO V–121 BL4
UNIT REPAIR
MAJOR COMPONENT DISASSEMBLY
Tools Required
DW240–020 Brake/Clutch Spring Compressor
DW240–050 Overdrive Brake Adapter
DW240–060–01 Brake Spring Compressor Bolt/Nut
DW240–070 1st & Reverse Brake Adapter
DW240–080 2nd Brake Adapter
DW240–090 Planetary Ring Gear Remover
DW240–150 Transaxle Case Side Bearing Outer Race
Adapter
DW240–170 Adapter Handle
DW260–021–02 Automatic Transaxle Overhaul Fixture
(81–40 LE)
DW260–041 Planetary Ring Gear Nut Removal/Installa-
tion Socket
Disassembly Procedure
1. Remove the transaxle assembly from the vehicle.
Refer to”Transaxle Assembly” in this section.
2. Install the transaxle assembly to the transaxle sup-
port stand using Automatic Transaxle Overhaul Fix-
ture DW260–021–02 (81–40 LE).
3. Remove the nut, washer and control lever.
4. Using a screwdriver, unstake the lock washer.
5. Remove the two bolts and nut and pull out the
transmission range (TR) switch.
6. Remove the two unions the transaxle case.
7. Remove the two O–rings from the unions.

AISIN AUTOMATIC TRANSAXLE 5A2 – 119
DAEWOO V–121 BL4
17. Remove the three bolts and oil strainer.
18. Remove the gasket from the oil strainer.
19. Remove the bolt and transmission fluid temperature
sensor with the clamp.
20. Disconnect the 5 solenoid connectors.
a. Lock–up control solenoid
b. Pressure control solenoid.
c. No.2 shift solenoid.
d. No.1 shift solenoid.
e. Timing solenoid
21. Support the valve body assembly and remove the
14 bolts.

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61. Remove the 2 plates, 2 discs and flange.
62. Remove the No. 2 one–way clutch and planetary
gear from the transaxle case.
63. Remove the No. 2 one–way clutch from the plane-
tary gear and remove the anti–rattle clip.
64. Fix the counter drive gear with the parking lock
pawl.

5A2 – 130IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
65. Remove the planetary ring gear nut using planetary
ring gear nut removal/installation socket DW
260–041.
Notice : Remove the nut without unstaking the planetary
ring gear. If chisel or other tool is used to unstake the plan-
etary ring gear, such impact may damage the bearing.
66. Remove the 2 bolts and parking lock pawl bracket.
67. Remove the parking lock pawl shaft, torsion spring
and parking lock pawl.
68. Remove the bolt and manual detent spring.

AISIN AUTOMATIC TRANSAXLE 5A2 – 131
DAEWOO V–121 BL4
69. Using a chisel and hammer, unstake and remove
the spacer.
70. Using a pin punch and hammer, drive out the pin.
71. Remove the manual valve lever shaft and manual
valve lever.
72. Remove the parking lock rod from the manual valve
lever.

5A2 – 134IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
82. Using a suitable puller, remove the counter driven
gear outer tapered roller bearing race and shim
from the transaxle case.
83. Using a driver, remove the oil seal from the trans-
axle case.
Notice : Be careful not to damage the transaxle case
when removing the oil seal using a driver.
84. 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.
85. Remove the 3 bolts and oil reservoir lock plate from
the transaxle housing.
86. Remove the bolt and No.1 transaxle apply pipe
clamp from the transaxle housing.
87. Remove the transaxle lube apply pipe and differen-
tial gear lube apply pipe from the transaxle housing.

AISIN AUTOMATIC TRANSAXLE 5A2 – 139
DAEWOO V–121 BL4
9. 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: 3.1mm (0.122 in.)
10. Install a new outer tapered roller bearing race into
the transaxle housing.
Notice : Press
fit the outer tapered roller bearing race un-
til it contacts the transaxle housing.
11. Install the transaxle lube apply pipe and differential
gear lube apply pipe to the transaxle housing.
12. Install the No.1 transaxle apply pipe clamp to the
transaxle housing with the bolt.
Tighten
Tighten the bolt to 5.4 NSm (48 lb–in).
13. Install the oil reservoir lock plate to the transaxle
housing with the 3 bolts.
Tighten
Tighten the bolts to 5.4 NSm (48 lb–in).

5A2 – 146IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
41. Install the parking lock rod to the manual valve le-
ver.
42. Install a new spacer to the manual valve lever.
43. Install the manual valve lever shaft and manual
valve lever.
44. Using a pin punch and hammer, drive in a new pin.

AISIN AUTOMATIC TRANSAXLE 5A2 – 147
DAEWOO V–121 BL4
45. Turn the spacer and lever shaft to align the small
hole for locating the staking position in the spacer
with the staking position mark on the lever shaft.
46. Using a pin punch, stake the spacer through the
small hole.
47. Check that the spacer does not turn.
48. Install the manual detent spring with the bolt.
Tighten
Tighten the bolts to 9.8 NSm (87 lb–in).
49. Install the parking lock shaft, torsion spring and
parking lock pawl.
Notice : Check that the edge of torsion spring fits into the
groove securely.

5A2 – 148IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
50. Install the parking lock pawl bracket with the 2
bolts.
Tighten
Tighten the bolts to 7.4 NSm (65 lb–in).
51. Using counter drive gear installation adapter
DW240–100 and brake spring compressor bolt/nut
DW240–060–01,install the planetary ring gear.
S Before installing the planetary ring gear, be sure
to replace the planetary ring flange of the plane-
tary ring gear with a new one.
52. Fix the counter drive gear with parking lock pawl.
53. Using planetary ring gear nut removal/installation
socket DW260–041, install a new nut.
Tighten
Tighten the nut to 9.8 NSm (87 lb–in).