tran DAEWOO LACETTI 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 11
DAEWOO V–121 BL4
BEARING PLATE
1. Strain Bolt Bridge
2. Bolt
3. Bolt
4. Bolt
5. Bearing Plate
6. Bolt
7. Pin
8. Blocking Pin
9. Compression Spring
10. Plug
11. Gear Shift Sliding Fork12. GearShift Shoe
13. Screw
14. Transaxle Cover
15. Transaxle Cover Gasket
16. Magnet
17. Bearing Plate Gasket
18. Bolt
19. Bolt
20. Bolt
21. Screw
22. Detent Sleeve

5B – 12IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
DIFFERENTIAL GEAR
1. Differential Gear Housing
2. Differential Gear
3. Speedometer Drive Gear
4. Washer
5. Side Gear
6. Bevel Differential Gear
7. Bevel Gear Disc
8. Differential Gear Shaft
9. Differential Spring Pin
10. Bolt11. Taper Roller Bearing
12. Differential Bearing Ring
13. Shaft Seal Ring
14. O–Ring
15. Differential Gear Bearing Flange
16. O–Ring
17. Locking Plate
18. Bolt
19. Bolt

FIVE–SPEED MANUAL TRANSAXLE 5B – 13
DAEWOO V–121 BL4
SHIFT LINKAGE

5B – 14IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
1. Gear Shift Control
2. Bolt
3. Gear Shift Tube Bellows
4. Clamp
5. Bolt
6. Gear Shift Control Mode
7. Gear Shift Guide Control
8. Pin
9. Clip
10. Bolt
11. 1st & 2nd Gear Shift Fork
12. 1st & 2nd Gear Shift Rod
13. Pin
14. 3rd & 4th Gear Shift Fork
15. 3rd & 4th Gear Shift Rod
16. Pin
17. 5th Speed Engaging Piece
18. Gear Shift Rod Pawl
19. Reverse Gear Shift Fork
20. Reverse Gear Shift Rod
21. Pin
22. Gear Shift Rod
23. Shift Finger24. Gear Shift Lever Cover
25. Gear Shift Inter Lever
26. Plate
27. Compression Spring
28. Bush
29. Retaining Ring
30. Gear Shift Cover Gasket
31. Bolt
32. Plug
33. Plug
34. Speedometer Driven Gear
35. Bolt
36. Differential Gear Cover Gasket
37. Differential Gear Cover
38. Screw
39. Backup Lamp Switch
40. O–ring
41. Pin
42. Pin
43. Sleeve
44. Bush

FIVE–SPEED MANUAL TRANSAXLE 5B – 15
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CHECKING FLUID LEVEL
1. With the vehicle on a level surface and the fluid in
the transaxle cold, remove the filler plug and check
the fluid level. The fluid should come to the bottom
edge of the plug hole.
2. If the level is low, add SAE 80 manual transaxle
fluid through the filler plug hole until the fluid begins
to run out.
3. Reinstall the filler plug and tighten it securely.
4. If the fluid is contaminated, drain the oil after re-
moving the differential gear cover.
SHIFT LINKAGE ADJUSTMENT
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
Important : All the gears must be easy to engage when
the vehicle is stationary, the engine is running, and the
clutch is disengaged.
3. Loosen the rod clamp bolt.

5B – 16IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
4. Remove the adjustment hole plug from the shift
lever cover.
5. Turn the gearshift rod and fully insert a 5 mm (0.2
inch) gauge pin into the adjustment hole.
6. Remove the boot from the console.
7. Pull the boot upward to expose the shift control le-
ver mechanism.
8. Position the gearshift lever close to left side of the
NEUTRAL position.
9. Insert a 5 mm (0.2 inch) gauge pin into the holes to
align the gearshift lever with the gearshift lever
housing.
10. Tighten the rod clamp bolt.
Tighten
Tighten the rod clamp bolt to 14 NSm (124 lb–in).
11. Remove .the 5 mm (0.2 inch) gauge pin from the
adjustment hole.
12. Install the adjustment hole plug.
13. Remove the 5 mm (0.2 inch) gauge pin from the
gearshift lever.
14. Install the boot to the console.
15. Connect the negative battery cable.

FIVE–SPEED MANUAL TRANSAXLE 5B – 17
DAEWOO V–121 BL4
GEARSHIFT LEVER
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
Removal Procedure
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
3. Disconnect the boot from the console cover.
4. Lift the console cover upward to expose the shift
control lever mechanism.
5. Rotate the gearshift lever stop clamp and remove it.
6. Remove the gearshift lever from the gearshift lever
shaft.
Installation Procedure
1. Install the gearshift lever into the gearshift lever
shaft.
2. Install the gearshift lever stop clamp.
3. Rotate the gearshift lever stop clamp to secure it.
4. Lower the boot and connect it to the console cover.
5. Connect the negative battery cable.

5B – 18IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
GEARSHIFT LEVER HOUSING
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the rod clamp. Refer to ”Shift Linkage Ad-
justment” in this section.
3. Remove the console.
4. Remove the gearshift lever housing bolts and the
gearshift lever housing.
Installation Procedure
1. Install the gearshift lever housing and the gearshift
lever housing bolts.
Tighten
Tighten the gearshift housing bolts to 7 NSm ( 62 lb–
in).
2. Adjust the shift linkage.
3. Install the console.
4. Connect the negative battery cable.
SPEEDOMETER DRIVEN GEAR
Removal Procedure
1. Disconnect the speedometer speed sensor electri-
cal connector.
2. Remove the speedometer housing retaining bolt.
3. Remove the speedometer–driven gear and the
speedometer housing.

FIVE–SPEED MANUAL TRANSAXLE 5B – 19
DAEWOO V–121 BL4
Installation Procedure
1. Coat the O–ring with petroleum jelly.
2. Install the speedometer–driven gear and the
speedometer housing.
3. Install the speedometer housing retaining bolt.
Tighten
Tighten the speedometer housing retaining bolt to 4
NSm (35 lb–in).
4. Connect the speedometer speed sensor electrical
connector.
SHIFT LINKAGE ASSEMBLY
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the rod clamp. Refer to ”Shift Linkage Ad-
justment” in this section.
3. Remove the clip and the bolt from universal joint.
4. Separate the universal joint from the transaxle.
5. Remove the fixing shaft pin and separate the link-
age connection part from the transaxle rear mount-
ing bracket.
6. Remove the shift linkage assembly.

5B – 20IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Install the shift linkage assembly.
2. Install the fixing shaft pin and connect the linkage
connection part to the transaxle rear mounting
bracket.
3. Install the universal joint to the transaxle.
4. Install the clip and the bolt from universal joint.
5. Install the rod clamp. Refer to ”Shift Linkage Adjust-
ment” in this section.
6. Adjust the shift linkage. Refer to ”Shift Linkage Ad-
justment” in this section.
7. Connect the negative battery cable.
DRIVE AXLE SEAL
Tools Required
KM–519 Ring Installer
Removal Procedure
Notice : Do not damage the bearing adjusting ring with the
pry bar.
1. Remove the drive axle from the transaxle. Refer to
Section 3B, Manual Transaxle Drive Axle.
2. Remove the drive axle seal by lifting the outer lip of
the seal with a pry bar.
Installation Procedure
1. Install the new drive axle seal using the ring install-
er KM–519 and a hammer.
2. Coat the seal lip with the transaxle fluid.
3. Install the drive. Refer to Section 3B, Manual Trans-
axle Drive Axle.