lock DAEWOO LACETTI 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 5
DAEWOO V–121 BL4
DIAGNOSIS
ISOLATE NOISE
Identify the cause of any noise before attempting to repair
the clutch, the transaxle, or their related link–ages.
Symptoms of trouble with the clutch or the manual trans-
axle include:
S A great effort required to shift gears.
S The sound of gears clashing and grinding.
S Gear blockout.
Any of these conditions requires a careful analysis. Make
the following checks before disassembling the clutch or
the transaxle for repairs.
Road Travel Noise
Many noises that appear to come from the transaxle may
actually originate with other sources such as the:
S Tires.
S Road surfaces.
S Wheel bearings.
S Engine.
S Exhaust system.
These noises may vary according to the:
S Size of the vehicle.
S Type of the vehicle.
S Amount of insulation used in the body of the ve-
hicle.
Transaxle Noise
Transaxle gears, like any mechanical device, are not ab-
solutely quiet and will make some noise during normal op-
eration.
To verify suspected transaxle noises:
1. Select a smooth, level asphalt road to reduce tire
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lu-
bricants thoroughly.
3. Record the speed and the gear range of the trans-
axle when the noise occurs.
4. Check for noises with the vehicle stopped, but with
the engine running.
5. Determine if the noise occurs while the vehicle op-
erates in:
S Drive – under a light acceleration or a heavy
pull.
S Float – maintaining a constant speed with a light
throttle on a level road.
S Coast – with the transaxle in gear and the
throttle partly or fully closed.
S All of the above.
Bearing Noise
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise
can be confused easily. Since side bearings are pre–
loaded, a differential side bearing noise should not dimin-
ish much when the differential/transaxle is run with the
wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound
that will continue when the vehicle is coasting and the
transaxle is in NEUTRAL. Since wheel bearings are not
pre–loaded, a wheel bearing noise should diminish con-
siderably when the wheels are off the ground.
Other Noise
Brinelling
A brinelled bearing causes a ”knock” or ”click” approxi-
mately every second revolution of the wheel because the
bearing rollers do not travel at the same speed as the
wheel. In operation, the effect is characterized by a low–
pitched noise.
A brinelled bearing is caused by excessive thrust which
pushes the balls up on the pathway and creates a triangu-
lar–shaped spot in the bearing race. A brinelled bearing
can also be caused from pressing one race into position
by applying pressure on the other race.
A false indication of a brinelled bearing occurs as a result
of vibration near the area where the bearing is mounted.
Brinelling is identified by slight indentations, resulting in a
washboard effect in the bearing race.
Lapping
Lapped bearing noise occurs when fine particles of abra-
sive materials such as scale, sand, or emery circulate
through the oil in the vehicle, causing the surfaces of the
roller and the race to wear away. Bearings that wear loose
but remain smooth, without spalling or pitting, are the re-
sult of dirty oil.
Locking
Large particles of foreign material wedged between the
roller and the race usually causes one of the races to turn,
creating noise from a locked bearing. Pre–loading regular
taper roller bearings to a value higher than that specified
also can result in locked bearings
Pitting
Pitting on the rolling surface comes from normal wear and
the introduction of foreign materials.
Spalling
Spalled bearings have flaked or pitted rollers or races
caused by an overload or an incorrect assembly that re-
sults in a misalignment, a cocking of bearings, or adjust-
ments that are too tight.
After completing these checks, refer to the ”Diagnosis
Chart” in this section.

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 – 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 ).

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 – 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.

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.