tran DAEWOO LACETTI 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 31
DAEWOO V–121 BL4
24. Remove the input drive fifth–gear snap ring.
25. Remove the input drive fifth gear using the fifth–
gear puller KM–553–A.
26. Remove the bolts and the fifth–gearshift connector
from the bearing plate using the pawl.
27. Remove the four shift–rod plugs using the shift rod
remover J–42469 and the slide hammer J–6125–B.

5B – 32IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
28. Remove the spring and the rod lock pin from the
small plug hole.
29. Remove the pin from the reverse gearshift rod/fork
assembly.
30. Remove the reverse gearshift rod/fork assembly
from the bearing plate.
31. Remove the bolts from the support bracket.

FIVE–SPEED MANUAL TRANSAXLE 5B – 33
DAEWOO V–121 BL4
32. Remove the first–second gearshift fork holding pin.
33. Drive the first–second gearshift rod out until it is just
free of the bearing plate.
34. Remove the support bracket from the bearing plate.
35. Remove the third–fourth gearshift fork holding pin
and the third–fourth gearshift rod.

5B – 34IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
36. Remove the fifth gearshift lever from the bearing
plate.
37. Remove the first–second gearshift rod.
38. Compress the snap ring holding the mainshaft and
secure it with the snap ring retainer J–36633.
39. Hold the snap ring open at the base of the input
shaft using the snap ring pliers.
40. Remove the mainshaft assembly and the input
shaft assembly from the bearing plate.

FIVE–SPEED MANUAL TRANSAXLE 5B – 35
DAEWOO V–121 BL4
INPUT SHAFT AND CLUSTER GEAR
Tools Required
J–22912–01 Universal Bearing Puller
Disassembly Procedure
1. Remove the detent screw at the end of the input
driveshaft.
2. Remove the snap ring at the base of the gear clus-
ter.
3. Press the input driveshaft from the input shaft clus-
ter gear using the universal bearing puller
J–22912–01.
4. Remove the cluster shaft bearing from the input
shaft gear cluster using universal bearing puller
J–22912–01.

5B – 36IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
Assembly Procedure
1. Press the cluster shaft bearing onto the input shaft
gear cluster.
2. Press the input driveshaft into the input shaft gear
cluster assembly.
3. Install the snap ring at the base of the gear cluster.
4. Install the detent screw at the end of the input dri-
veshaft.
Tighten
Tighten the input driveshaft detent screw to 15 NSm
(11 lb–ft).

FIVE–SPEED MANUAL TRANSAXLE 5B – 37
DAEWOO V–121 BL4
MAINSHAFT
Tools Required
J–22912–01 Universal Bearing Puller
Disassembly Procedure
1. Remove the mainshaft bearing using the universal
bearing puller J–22912–01.
2. Remove the snap ring.
3. Remove the first gear, the flat–type first–gear
needle bearing, and the mainshaft wear plate.
4. Remove the synchronizer hub sleeve that contains
the synchronizer spring.
5. Remove the outer blocking ring.

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.

FIVE–SPEED MANUAL TRANSAXLE 5B – 39
DAEWOO V–121 BL4
10. Remove the first–second gear blocking ring.
11. Remove the second gear using the universal bear-
ing puller J–22912–01.
12. Remove the second–gear needle bearing.
13. Remove the ring and the thrust washer.

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.