tran DAEWOO LACETTI 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 21
DAEWOO V–121 BL4
TRANSAXLE ASSEMBLY
Tools Required
J–28467–B Engine Support Fixture
Removal Procedure
1. Install the engine support fixture J–28467–B.
2. Remove the battery and battery tray. Refer to Sec-
tion 1E, ENGINE ELETRICAL.
3. Remove the shift linkage assembly. Refer to ”Shift
Linkage Adjustment” in this section.
4. Remove the drive axle shaft. Refer to Section 3B,
Manual Transaxle Drive Axle.
5. Disconnect the backup lamp switch electrical con-
nector.
6. Disconnect the speedometer speed sensor electri-
cal connector.
7. Remove the pin and the clutch release cylinder
pipe.
8. Remove the damping block connection nut and
bolt.
9. Remove the three rear mounting bracket bolts.
10. Remove the rear mounting bracket from the trans-
axle.

5B – 22IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
11. Remove the two rear damping block retaining bolts.
12. Remove the rear damping block from the front
cross member.
13. Remove the two cage retaining bolts.
14. Remove the three transaxle upper mounting brack-
et bolts.
15. Remove the upper mounting bracket and cage.
16. Remove the three transaxle upper retaining bolts.
17. Support the transaxle with a transaxle support jack.

FIVE–SPEED MANUAL TRANSAXLE 5B – 23
DAEWOO V–121 BL4
18. Remove the seven transaxle lower retaining bolts.
19. Remove the transaxle.
Notice : Rest the transaxle only in an upright position.
20. Slide the transaxle sideways away from the engine
block.
21. Lower the transaxle.
Installation Procedure
1. Support the transaxle with a transaxle support jack.
2. Install the transaxle by inserting the transaxle input
shaft into the clutch disc and sliding the transaxle
sideways into the engine block.
3. Install the seven transaxle lower retaining bolts.
Tighten
Tighten the transaxle lower retaining bolts(a) to 73
NSm ( 54 lb–ft ).
Tighten the transaxle lower retaining bolt(b) to 31 NSm
( 23 lb–ft ).
Tighten the transaxle lower retaining bolts(c) to 21
NSm ( 15 lb–ft ).

5B – 24IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
4. Install the three transaxle upper retaining bolts.
Tighten
Tighten the transaxle upper retaining bolts to 73 NSm
(54 lb–ft ).
5. Install the cage retaining bolt and cage.
6. Install the three transaxle upper mounting bracket
bolts and bracket.
Tighten
Tighten the transaxle upper mounting bracket bolts to
48 NSm (35 lb–ft ).
7. Install the two rear damping block retaining bolts.
Tighten
Tighten the rear damping block retaining bolts to 68
NSm (50 lb–ft ).
8. Install the rear damping block from the front cross
member.
9. Install the three rear mounting bracket bolts and the
bracket.
Tighten
Tighten the rear mounting bracket bolts to 90 NSm (66
lb–ft ).
10. Install the damping block connection nut and bolt.
Tighten
Tighten the damping block connection nut and bolt to
68 NSm (50 lb–ft ).

FIVE–SPEED MANUAL TRANSAXLE 5B – 25
DAEWOO V–121 BL4
11. Connect the clutch release cylinder pipe.
12. Connect the speedometer speed sensor electrical
connector.
13. Connect the backup lamp switch electrical connec-
tor.
14. Remove the engine support fixture J–28467–B.
15. Install the drive axle shaft. Refer to Section 3B,
Manual Transaxle Drive Axle.
16. Install the shift linkage assembly. Refer to ”Shift
Linkage Assembly” in this section.
17. Install the battery and battery tray. Refer to Section
1E, ENGINE ELETRICAL.
18. Inspect the fluid level. Refer to ”Checking Fluid Lev-
el” in this section.

5B – 26IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
UNIT REPAIR
MAJOR COMPONENT DISASSEMBLY
Tools Required
J–6125–B Slide Hammer
J–22888–20–A BearingPuller with J–22888–35 Puller
Legs
KM–553–A Fifth Gear Puller
J–36633 Snap Ring Retainer
KM–113–2 Base
J–42469 Shift Rod Remover
KM–552 Fixture
Disassembly Procedure
1. Remove the transaxle from the vehicle. Refer to
”Transaxle Assembly” in this section.
2. Remove the filler plug at the cover.
3. Remove the bolts from the gearshift lever cover.
4. Remove the gearshift lever cover.

FIVE–SPEED MANUAL TRANSAXLE 5B – 27
DAEWOO V–121 BL4
5. Bolt the gearshift lever cover to the fixture KM–552.
6. Position the fixture KM–552 into the base
KM–113–2.
7. Remove the snap ring, the bushing, the spring, and
the intermediate lever.
8. Remove the shift finger lever pin.
9. Remove the gearshift rod and the shift finger lever.

5B – 28IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
10. Remove the bolt and the speedometer–driven gear
from the transaxle housing.
11. Remove the transaxle cover bolts.
12. Remove the transaxle cover.
13. Shift the transaxle into second gear.
14. Remove the bearing plate bolts.

FIVE–SPEED MANUAL TRANSAXLE 5B – 29
DAEWOO V–121 BL4
15. Remove the bearing plate from the case with the
shafts attached.
16. Shift the transaxle into reverse (R).
17. Bolt the bearing plate to the fixture KM–552 and
install the fixture KM–552 into the base KM–113–2.
18. Remove the bolts and the fifth–gear fork from the
bearing plate.
19. Remove the mainshaft–driven fifth–speed assembly
snap ring.

5B – 30IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
20. Remove the fifth driven gear synchronizer sleeve
and the synchronizer gear using the bearing puller
J–22888–20–A with the puller legs J–22888–35.
21. Remove the mainshaft–driven fifth–gear assembly.
22. Remove the brass synchronizer ring.
23. Remove the needle bearing, the retaining ring, and
the thrust washers.