differential DAEWOO MATIZ 2003 Service User Guide

FIVE-SPEED MANUAL TRANSAXLE 5B–29
DAEWOO M-150 BL2
D103B720
21. Remove the gear unit.

Remove the gear unit and the shift shaft assem-
bly together (1).
Notice: Be careful not to damage teeth of the counter
shaft pinion and the differential ring gear.

Remove the high and the low speed shift shaft
assembly from the gear unit.
D103B721
22. Remove the differential assembly.

Insert a wooden stick into the lower side of differ-
ential (1).

Remove the differential assembly by moving it
right and left (2).
D103B722
23. Remove the related parts of the transaxle case (Left
Side).

Remove the bolt (1).

Remove the oil gutter (2).

Remove the bolts (3).

Remove the oil plate (4).

Remove the differential left side oil seal using a
hammer and a copper chisel (5).
D103B723

Remove the bolts (6).

Remove the case cap (Left Side) (7).

Remove the case cap O–ring (Left Side) (8).

Remove the oil level plug (including steel gasket)
(9).

Remove the counter shaft bearing outer race us-
ing a hammer and the gear, bearing installer DW
09940–53111.

5B–30 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B724
24. Remove the related parts of the transaxle case
(Right Side).

Remove the input shaft oil seal using a screwdriv-
er (1).

Remove the differential left side oil seal using a
hammer and a copper chisel (2).
D103B725
Synchronizer Sleeve and Shift Fork
Inspection
1. Measure the clearance between synchronizer sleeve
and shift fork and if the clearance exceeds the limit,
replace the shift fork.
Unit : mm (in.)

Clearance Between
Standard Limit

Clearance Between
Sleeve and Shift
Fork
0.2 ∼0.6
(0.008∼0.024)1.0
(0.039)
D103B726
Assembly Procedure
1. Install the related parts of the transaxle case (Right
Side).

Install the input shaft oil seal using the bushing
seal installer DW09943–78210.

Install the differential right side oil seal using the
bushing, seal installer 09913–76010.
Important: Use only a new oil seal.
Important: Coat the transaxle inner parts with gear fluid
when installing.
D13B727A
2. Install the related parts of the transaxle case (Left
Side).

Install the oil plate with the bolts.

Install the oil gutter with the bolt.

Install the oil level plug (including steel gasket).
a. Oil level plug.
Tighten
Tighten the oil level plug to 36–54 Nm (26–40 lb-ft).

Install the left side case cap with the bolts (includ-
ing O–ring) (1).

FIVE-SPEED MANUAL TRANSAXLE 5B–31
DAEWOO M-150 BL2
D13B727A
Tighten
Tighten the bolt to 8–12 Nm (71–106 lb-in).
b. Case cap retaining bolt.

Install the differential left side oil seal using the oil,
seal installer KM519.
D103B728
3. Install the differential assembly to the right side of
transaxle case.
a. Differential assembly.

When the differential ring gear surface is lower
than the right side of transaxle case surface, it is
installed correctly.
D103B729
4. Install the low and the high speed shift shaft assem-
bly to the gear unit.
5. Install the gear unit.

Push the gear unit by matching it with the input and
the counter shaft hole (1).
Notice: Be careful not to damage teeth of the counter
shaft pinion and the differential ring gear.
D13B730A
6. Install the fifth–reverse gear shift shaft.
7. Install the reverse idle gear shaft assembly and the
reverse gear shift lever.

Install the reverse idle gear shaft assembly (1).
Important: Match the marking of the reverse idle gear
shaft bolt hole with the protrusion of the transaxle case
(Right Side).

Install the reverse gear shift lever (2).
Tighten
Tighten the bolts to 18–28 Nm (13–21 lb-ft).

FIVE-SPEED MANUAL TRANSAXLE 5B–41
DAEWOO M-150 BL2
D103B762
6. Install the input shaft fourth gear bearing and the
fourth gear.
a. Fourth gear.
b. Fourth gear bearing.
D103B763
7. Install the input shaft left side bearing and the fifth
gear spacer.

Install the following parts using the gear, bearing
installer DW09925–98221 and a hammer.
a. Fifth gear spacer.
b. Input shaft left side bearing.
D103B764
8. Install the input shaft right side bearing.

Install the bearing to the input shaft using the gear,
bearing installer DW09925–98221 and a hammer
(1).
9. Install the gear unit. Refer to “Gear Unit” in this sec-
tion.
D103B765
COUNTER SHAFT
Tools Required
09913–76010 Bushing, Seal Installer
DW09913–80112 Gear, Bearing Installer
DW09921–57810 Gear, Bearing Remover
DW09925–98221 Gear, Bearing Installer
DW09940–53111 Gear,Bearing Installer
DW220–020–01 Differential Bearing Puller
DW220–020–02 Differential Bearing Plate Adapter
DW220–020–03 Differential Bearing Plate Adapter
KM466–A Gear, Bearing Remover/Installer

5B–48 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B787
Inspection Procedure – Shift Fork
1. Measure the end thickness of shift fork and replace if
below limit.
Unit : mm (in.)


Shift fork end
thickness (mm)
Standard
Limit
Low Speed Shift Fork8.7 (0.343)8.1 (0.319)
High Speed Shift Fork7.8 (0.307)7.2 (0.283)
Fifth Gear Shift Fork7.8 (0.307)7.2 (0.283)
D103B788
Low Speed
Shift ShaftHigh Speed
Shift Shaft5th/Reverse
Shift Shaft
Assembly Procedure
1. Install in the reverse order of removal.
Important: Use only new fork fin and yoke pin.
D103B789
DIFFERENTIAL
Disassembly Procedure
1. Remove the differential assembly. Refer to “Gear
Unit” in this section.
2. Remove the differential ring gear.

Fix the differential assembly to a vise with protec-
tor.

Remove the bolts (1).

Remove the ring gear (2).
D103B790
3. Remove the pinion gear pin.

Remove the pin using a pin punch and a hammer
(1).

FIVE-SPEED MANUAL TRANSAXLE 5B–49
DAEWOO M-150 BL2
D103B791
4. Remove the pinion gear shaft.

Remove the shaft from the case (1).
D103B792
5. Remove the pinion gears and the side gears.

Remove the pinion gears and the washers (1).
Important: Remove the pinion gear and the washer by
rotating the side gear.

Remove the side gears (2).

Remove the adjust shims from the side gears (3).
D13B793A
6. Remove the differential right side bearing and
speedometer drive gear.

Remove the right side bearing using the differential
bearing puller DW220–020A–01 and the differen-
tial bearing plate adapter DW220–020A–02.

Remove the speedometer drive gear (1).
D13B794A
7. Remove the differential left side bearing.

Remove the left side bearing using the differential
bearing puller DW220–020A–01 and the differen-
tial bearing plate adapter DW220–020A–03.

5B–50 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B795
Side Gear Play Inspection
1. Measure the axle direction play of side gear and re-
place a side gear washer if it exceeds limit.
UNIT : mm (in.)


Thrust Free Play of
Differential Side

0.05–0.33
(0.0020–0.0130)
UNIT : mm (in.)
0.90 (0.0354) 0.95 (0.0374)
Thrust Adjusting 1.00 (0.0394) 1.05 (0.0413)

Thrust Adjusting
Shim
1.10 (0.0433) 1.15 (0.0453)
1.20 (0.0472)
D103B796
2. After checking for worn or scratched thrust adjusting
shim, replace it if necessary.
a. Side gear.
b. Driver.
D103B797
Assembly Procedure
1. Install the differential left side bearing.

Insert the left side bearing (1).

Install the left side bearing using the bushing, seal
installer 09913–76010 and a hammer.
Important: Coat the inner parts; bearing, washer, shim
etc. with gear fluid.
D103B798
2. Install the speedometer drive gear and differential
right side bearing.

Insert the speedometer drive gear(1).

Insert the differential right side bearing (2).

Install the right side bearing using the bushing,
seal installer 09913–76010 and a hammer.

FIVE-SPEED MANUAL TRANSAXLE 5B–51
DAEWOO M-150 BL2
D103B799
3. Install the side gears and the pinion gears.

Insert the trust adjusting shims to the side gears.

Install the side gears (1).

Install the pinion gears and washers (2).
Important: Install the pinion gears and washers simul-
taneously.
D103B800
4. Install the pinion gear shaft and pin.

Insert the shaft into the gear pin hole by rotating
(1).

Press the pin using a pin punch and a hammer (2).
Important: Use only new pin.
D13B801A
5. Install the differential ring gear.

Fix the differential assembly to a vise.

Install the ring gear with the bolts (1).
Tighten
Tighten the bolts to 80–100 Nm (59–74 lb-ft).
6. Install the differential assembly. Refer to “Gear Unit”
in this section.

5B–52 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
GeneralTypeForward gear–Synchronized
mesh type–
Reverse gear–Sliding mesh
type–
Gear ratio1st–3.818–
2nd–2.210–
3rd–1.423–
4th–1.029–
5th–0.837–
Reverse–3.583–
Final drive ratio–4.444–
Fluid capacityL(qt)2.1 (2.21)–
Fluid classification–75W-85 (GL-4)–
ServiceKey groove width of1st gearmm(in.)8.2 (0.323)8.6 (0.339)
synchronizer ring2nd, 3rd, 4th gearmm(in.)9.6 (0.378)10.0 (0.394)
5th gearmm(in.)9.4 (0.370)9.8 (0.386)
Shift fork end
thicknessLow speed shift fork
(1st~2nd)mm(in.)8.7 (0.343)8.1 (0.319)
High speed shift fork
(3rd~4th)mm(in.)7.8 (0.307)7.2 (0.283)
5th gear shift forkmm(in.)7.8 (0.307)7.2 (0.283)
Clearance between gear and synchronizer
ringmm(in.)1.0 (0.039)0.5 (0.020)
Clearance between sleeve and shift forkmm(in.)0.2 – 0.6
(0.008 – 0.024)1.0 (0.039)
Thrust free play of differential side gearmm(in.)0.05 – 0.33
(0.002 – 0.013)–
Speedometer gear ratio(Driven/Drive)–17/18 (0.944)–

FIVE-SPEED MANUAL TRANSAXLE 5B–53
DAEWOO M-150 BL2
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
5th/Reverse Gear Shift Shaft Bolt10 – 167 – 12–
Back Up Light Switch Nut15 – 1811 – 13–
Counter Shaft 5th Gear Nut60 – 8044 – 59–
Crankshaft Position Sensor Bolt5 – 8–44 – 70
Differential Ring Gear Bolt80 – 10059 – 74–
Engine Mounting Front Bracket Bolt
(Cylinder Block Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolt
(Crossmember Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolts
(Crossmember Side)45 – 5533 – 41–
Engine Mounting Front Damping Bush Bolt/Nut
(Bracket Side)68 – 8351 – 61–
Front Exhaust Pipe Nut
(Exhaust Manifold Side/Muffler Side)25 – 3518 – 25–
Gear Shift Control Case Bolt18 – 2813 – 21–
Gear Shift Lever Bolt4 – 7–35 – 62
High Speed Shift Shaft Bolt10 – 167 – 12–
Low Speed Shift Shaft Bolt10 – 167 – 12–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–
Radiator Lower Hose Bracket Bolts8 – 15–70 – 132
Reverse Idle Gear Shaft Bolt18 – 2813 – 21–
Reverse Shift Lever Bolt18 – 2813 – 21–
Select Cable Nut(Shift Lever Side)8 – 12–71 – 106
Select Lever Bolt18 – 2813 – 21–
Side Cover Plate Screw6 – 7–53 – 62
Shift Guide Bolt18 – 2813 – 21–
Shift Interlock Bolt18 – 2813 – 21–
Side Cover Bolt8 – 12–71 – 106
Speedometer Driven Gear Bolt4 – 7–35 – 62
Starter Motor Bolt18 – 2813 – 21–
Transaxle Case Bolt15 – 2211 – 16–
Transaxle Case(left) Cap Bolt8 – 12–71 – 106
Transaxle Lower Bolt and Nut(Engine Side)55 – 6541 – 48–
Transaxle Mounting Bolt(Body Side)45 – 5533 – 41–
Transaxle Mounting Bolt and Nut(Transaxle Side)55 – 6541 – 48–
Transaxle Upper Bolt(Engine Side)55 – 6541 – 48–
Transaxle Under Cover Bolt35 – 5525 – 41–