Reverse DAEWOO LACETTI 2004 Service Manual PDF

AISIN AUTOMATIC TRANSAXLE 5A2 – 233
DAEWOO V–121 BL4
Reverse Gear
PositionSolenoidClutchBrake1 way
Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
RV<9
km/
hONONONOFFOFFONOFFOFFONOF
–FOF
–F
V
9km
/hONONONOFFOFFOFFOFFOFFOFFOF
–FOF
–F
Reverse Gear
1. Input shaft rotates clockwise.
S Reverse clutch (C3) operates.(Connect input shaft to rear planetary sun gear)
2. Planetary long pinion rotates itself counterclockwise.
3. 1st & reverse brake(3) operates. (Lock rotates planetary carrier)
4. Ring gear rotates counterclockwise.

FIVE–SPEED MANUAL TRANSAXLE 5B – 7
DAEWOO V–121 BL4
Checks Action
Check for a noise in the fourth gear (4) only.S Replace any chipped, scored, or worn fourth gear or
output gear.
S Replace any worn third–fourth gear synchronizer.
S Replace any worn fourth–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the fifth gear (5) only.S Replace any chipped, scored, or worn fifth gear or
output gear.
S Repair any worn fifth–gear synchronizer.
S Replace any worn fifth–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the reverse (R) gear only.S Replace any chipped, scored, or worn reverse idler
gear, idler–gear bushing, input gear, or output gear.
S Replace any worn first–second gear synchronizer.
S Replace any worn output gear.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
Check for a noise in all gears.S Add sufficient lubricant.
S Replace any worn bearings.
S Replace any chipped, scored, or worn input–gear
shaft or output–gear shaft.
Check for the transaxle slipping out of gear.S Adjust or replace the linkage, as needed.
S Adjust, repair, or replace any binding shift linkage.
S Tighten or replace the input–gear bearing retainer, as
needed.
S Repair or replace any worn or bent shift fork.
Check for a leak in the area of the clutch.S Repair the transaxle casing.
S Replace any damaged release bearing guide.
Check for a leak at the center of the transaxle.S Repair the transaxle casing.
S Repair the shift mechanism.
S Replace the damaged backup lamp switch.
Check for a leak at the differential.S Adjust or replace the bearing retainers.
S Tighten or replace the differential cover.
S Adjust or replace the drive axle shaft seals.

5B – 8IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
Checks Action
Check for a hard shift.S Replace any damaged release–bearing guide.
S Adjust, repair, or replace the shift mechanism.
S Adjust, repair, or replace the clutch–release system.
S Replace any chipped, scored, or worn fifth–gear syn-
chronizer.
S Replace any chipped, scored, or worn first–second
gear synchronizer.
S Replace any worn third–fourth gear synchronizer.
S Adjust, repair, or replace the shift lever and the rods.
Check for a clashing of gears.S Replace any damaged release–bearing guide.
S Adjust, repair, or replace the clutch–release system.
S Replace the chipped, scored, or worn input shaft/
gear–cluster gears.
S Replace any worn fifth–gear synchronizer.
S Replace any worn fifth–gear/bearing.
S Replace any worn first–gear/bearing.
S Replace any worn first–second gear synchronizer.
S Replace any worn second–gear/bearing.
S Replace any worn third–gear/bearing.
S Replace any worn third–fourth synchronizer.
S Replace any worn fourth–gear/bearing.
S Replace any worn reverse–idler gear.

5B – 10IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
1. Roller Bearing
2. Transaxle Main Shaft
3. Washer
4. Washer Retaining Ring
5. 4th Speed Gear
6. Needle Cage
7. Synchronizer Ring
8. Shift Sleeve
9. Synchronizer Key
10. 3rd & 4th Synchronizer Spring
11. Washer
12. Circlip
13. 3rd Speed Gear
14. Washer
15. Washer Retaining Ring
16. 2nd Speed Gear
17. Needle Cage
18. Inside Synchronizer Ring
19. Intermediate Ring
20. Outside Synchronizer Ring
21. Sliding Gear
22. 1st & 2nd Synchronizer Key
23. 1st & 2nd Synchronizer Spring
24. Washer
25. Circlip
26. 1st Speed Gear
27. Needle Cage28. Needle Cage
29. Main Shaft Disc
30. Retaining Ring
31. Groove Ball Bearing
32. Washer
33. Retaining Ring
34. 5th Speed Gear
35. Needle Cage
36. Synchronizer Ring
37. 5th Shift Sleeve
38. 5th Synchronizer Spring
39. 5th Synchronizer Key
40. Retaining Ring
41. Needle Sleeve
42. Input Drive Shift
43. Input Shaft Cluster Gear
44. Bolt
45. Retaining Ring
46. Cluster Bearing Ring
47. Groove Ball Bearing
48. Cluster 5th Speed Gear
49. Retaining Ring
50. Washer
51. Reverse Idler Gear
52. Reverse Idler Gear Shaft
53. Ball

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 – 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 – 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.

5B – 58IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
12. Install the support bracket bolts.
Tighten
Tighten the support bracket bolts to 7 NSm (62 lb–in).
13. Install the reverse gearshift rod/fork onto the bear-
ing plate.
14. Install the reverse gearshift rod/fork holding pin.
15. Install the rod lock pin and spring into the small plug
hole.

FIVE–SPEED MANUAL TRANSAXLE 5B – 63
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FIVE–SPEED MANUAL TRANSAXLE
This five–speed transaxle assembly is a transmission of
constant–mesh design.
Combined in the assembly are:
S All forward gears.
S The reverse gear.
S The differential output.
The basic components of the five–speed transaxle as-
sembly units are the:
S Transaxle case.
S Input shaft.
S Input shaft gears.S Output shaft.
S Output shaft gears.
S Ring gear and differential assembly.
Forward Gear
Shifting to a forward gear is accomplished through a com-
bination of synchronizers with blocker rings controlled by
sliding shift forks.
Reverse Gear
Reverse gear is not synchronized and uses a sliding idler
gear arrangement.
Differential Assembly
The differential is a conventional arrangement of gears
that is supported by tapered roller bearings. The final out-
put gear turns the ring gear and differential assembly
which turns the drive axle shafts.

5C – 8ICLUTCH
DAEWOO V–121 BL4
CLUTCH RELEASE POINT
ADJUSTMENT
Adjustment Procedure
1. Apply the parking brake.
2. Run the engine at idle speed.
3. While you move the shift lever into the reverse
position, depress the clutch pedal slowly and mea-
sure the distance between the point when gear
noise is not heard and the point the clutch pedal is
completely depressed. The distance should be 30
to 40 mm (1.2 to 1.6 inches).
4. If the distance is not within the specified value,
check the following:
S Clutch pedal height
S Clutch pedal play
S Air in the system
S Clutch cover and disc pressure plate
AIR BLEEDING
Bleed the hydraulic system to remove the air which en-
tered when the pipes were disconnected for repairs. The
clutch/brake fluid in the clutch/brake reservoir must be
maintained at the MIN level or higher during air bleeding.
1. Attach a vinyl hose to the bleeder plug. Place the
other end of the vinyl tube in a glass container half–
filled with brake fluid.
2. Slowly pump the clutch pedal several times.
3. While you press the clutch pedal, loosen the bleed-
er screw until the fluid starts to run out. Close the
bleeder screw.
4. Repeat Step 3 until there are no air bubbles in the
fluid.
5. Fill the reservoir with brake fluid up to the proper
level.
PRESSURE PLATE AND CLUTCH
DISC
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the transaxle from the vehicle. Refer to
Section 5B, Five–Speed Manual Transaxle.
3. Remove the pressure plate bolts and the pressure
plate.
Important : Support the pressure plate when you remove
the last bolt.