clutch DAEWOO MATIZ 2003 Service Owner's Manual

5B–24 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
MAINTENANCE AND REPAIR
UNIT REPAIR
D13B701A
GEAR UNIT
Tools Required
09913–76010 Bushing, Seal Installer
DW09940–53111 Gear, Bearing Installer
DW09943–78210 Bushing, Seal Installer
DW220–010A Transaxle Fixture
KM519 Oil Seal Installer
Disassembly Procedure
1. Remove the manual transaxle. Refer to “Manual
Transaxle Assembly” in this section.
2. Position the manual transaxle to a transaxle stand us-
ing the transaxle fixture DW220–010.
D13B7021
3. Remove the related clutch parts. Refer to Section 5C,
Clutch.
4. Remove the manual transaxle mounting bracket.

Remove the bolts (1).

Remove the nut (2).

Remove the mounting bracket (3).
D103B703
5. Disconnect the backup light switch and speedometer
driven gear assembly.

Remove the nut (1).

Disconnect the backup light switch (2).

Remove the bolt (3).

Remove the speedometer driven gear assembly
(4).

5B–28 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B716
17. Remove the transaxle case (Left).

Remove the bolts from the left side case (1).

Remove the bolts, stud bolts if equipped with
auto clutch.

Remove the bolts from the right side of case (2).

Remove the left side case by hitting with a rubber
hammer lightly.

Remove the sealant on the case.
D103B717
18. Remove the reverse gear shift lever.

Remove the bolts (1).

Remove the reverse gear shift lever (2).
D103B718
19. Remove the reverse idle gear shaft assembly.

Push the reverse idle gear toward inner case.

Pulling shaft and remove the reverse idle gear
and shaft (1).

Remove the reverse idle gear from the shaft.
D103B719
20. Remove the fifth–reverse gear shift shaft.
a. Fifth–reverse gear shift shaft.

5B–32 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B731A
8. Install the shift shaft ball and spring.

Install the third–fourth gear shift shaft ball and
spring.
Tighten
Tighten the bolt to 10–16 Nm (7–12 lb-ft) (a).

Install the fifth–reverse gear shift shaft ball and
spring.
Tighten
Tighten the bolt to 10–16 Nm (7–12 lb-ft) (b).
Important: Install the fifth–reverse gear shift shaft
spring marked when removing.
D13B732A
9. Install the transaxle left side case.

Coat the transaxle case with recommended seal-
ant.
Transaxle Case Sealant THREE BOND 1215

Install the transaxle left side case to the transaxle
right side case.
Tighten
Tighten the bolts to 15–22 Nm (11–16 lb-ft) (a).

Tighten the bolts (8), stud bolts (3) if equipped with
auto clutch.
Tighten the bolts to 15–22 Nm (11–16 lb-ft) (b).
D13B733A
10. Install the first–second gear shift shaft ball and
spring.
Tighten
Tighten the bolt to10–16 Nm (7–12 lb-ft) (a).
11. Install the reverse idle gear shaft bolt.
Tighten
Tighten the bolt to 18–28 Nm (13–21 lb-ft) (b).
D103B734
12. Install the counter shaft bearing outer race.

Install the counter shaft bearing outer race using
the gear, bearing installer DW09940–53111.
a. Bearing outer race.
Important: Check if the bearing and the outer race are
correctly installed by rotating counter shaft.

5B–36 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B744A
24. Install the backup light switch and the speedometer
driven gear assembly.

Install the backup light switch (1).
Tighten
Tighten the nut to 15–18 Nm (11–13 lb-ft) (a).

Install the speedometer driven gear assembly
(2).
Tighten
Tighten the bolt to 4–7 Nm (35–62 lb-in) (b).

Install the hydraulic pump assembly (If equipped
with auto clutch). Refer to Section 5D, Auto
Clutch.
D13B7452
25. Install the transaxle mount.

Install the mount (1).
Tighten

Tighten the bolts to 55–65 Nm (41–48 lb-ft) (a).

Tighten the nut to 55–65 Nm (41–48 lb-ft) (b).
D13B701A
26. Install the related clutch parts. Refer to Section 5C,
Clutch.
27. Remove the transaxle assembly from transaxle
stand.

Remove the transaxle assembly using the trans-
axle fixture DW220–010A.
28. Install the transaxle assembly. Refer to “Manual
Transaxle Assembly” in this section.
D103B746
INPUT SHAFT
Tools Required
DW09921–57810 Gear, Bearing Remover
DW09925–98221 Gear, Bearing Installer
DW09940–53111 Gear, Bearing Installer
Disassembly Procedure
1. Remove the gear unit. Refer to “Gear Unit” in this
section.
2. Remove the input shaft right side bearing.

Position the bearing to the gear, bearing remover
DW09921–57810.

Remove the bearing by pressing (1).

DAEWOO M-150 BL2
SECTION 5C
CLUTCH
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.
TABLE OF CONTENTS
Description and Operation 5C-2. . . . . . . . . . . . . . . . . .
Driving Members 5C-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Driven Members 5C-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Members 5C-2. . . . . . . . . . . . . . . . . . . . . . .
Component Locator 5C-3. . . . . . . . . . . . . . . . . . . . . . . .
Clutch Components 5C-3. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 5C-4. . . . .
General Diagnosis 5C-4. . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pedal Operation 5C-5. . . . . . . . . . . . . . . . . . . .
Clutch Cable Adjustment 5C-5. . . . . . . . . . . . . . . . . . .
Repair Instruction 5C-6. . . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 5C-6. . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Plate, Clutch Disc and
Input Shaft Bearing 5C-6. . . . . . . . . . . . . . . . . . . . . . . .
Clutch Release Bearing, Shaft and Bushing 5C-8. . .
Clutch Release Arm 5C-10. . . . . . . . . . . . . . . . . . . . . .
Clutch Cable 5C-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pedal 5C-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 5C-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5C-13. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5C-13. . . . . . . . . .
Special Tools 5C-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5C-14. . . . . . . . . . . . . . . . . . . . . . .

5C – 2 CLUTCH
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRIVING MEMBERS
The driving members consist of two flat surfaces ma-
chined to a smooth finish. One of these is the rear face
of the engine flywheel, and the other is the pressure
plate. The pressure plate is fitted into a steel cover,
which is bolted to the flywheel.
DRIVEN MEMBERS
The driven member is the clutch disc with a splined hub
which is free to slide lengthwise along the splines of the
input shaft, but which drives the input shaft through
these same splines.The driving and driven members are held in contact by
spring pressure. This pressure is exerted by a dia-
phragm spring in the pressure plate assembly.
OPERATING MEMBERS
The clutch release system consists of the clutch pedal,
the clutch release shaft, the clutch cable, the release
arm and the release bearing. When pressure is applied
to the clutch pedal, the clutch release shaft pushes
against the release bearing by rotating. The bearing
then pushes against the diaphragm spring in the pres-
sure plate assembly, thereby releasing the clutch.

CLUTCH 5C–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
CLUTCH COMPONENTS
D13C4011
1 Clutch Disc
2 Pressure Plate
3 Release Bearing
4 Release Shaft
5 Release Shaft Bushing (No.1)
6 Release Shaft Bushing (No.2)7 Release Shaft Seal
8 Release Arm
9 Clutch Cable Adjusting Nut
10 Clutch Cable
11 Clutch Pedal

5C –4 CLUTCH
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
ConditionProbable CauseCorrection
Slipping Clutch
Improper clutch cable adjustment.
Adjust clutch cable.

Worn or oily contamination on clutch disc
surface.
Replace clutch disc.

Worn or oily contamination on pressure
plate, flywheel surface.
Replace pressure plate, flywheel.

Damaged or weakened diaphragm spring.
Replace pressure plate.

Rusted clutch cable.
Replace clutch cable.
Dragging Clutch
Improper clutch cable adjustment.
Adjust clutch cable.

Worn or weakened diaphragm spring.
Replace pressure plate.

Worn or rusted splines of input shaft or
clutch disc.
Replace input shaft or clutch disc.

Excessively wobbly clutch disc.
Replace clutch disc.

Worn clutch disc.
Replace clutch disc.
Fails to Release
Bent or damaged clutch disc.
Replace clutch disc.

Worn or rusted splines of input shaft or
clutch disc.
Replace input shaft or clutch disc.

Improper operation of clutch release shaft.
Replace clutch release shaft.
Pedal Stays on Floor
When Disengaged
Interfered clutch release bearing.
Lubricate and adjust clutch release
bearing.

Weakened diaphragm spring.
Replace pressure plate.
Clutch Vibration
Clutch facing with oily contamination.
Replace clutch disc.

Release bearing slides unsmoothly on input
shaft bearing retainer.
Lubricate retainer release bearing.

Wobbly clutch disc or poor facing contact.
Replace clutch disc.

Loose clutch disc rivets.
Replace clutch disc.

Weakened clutch disc torsion spring.
Replace clutch disc.

Distorted pressure plate or flywheel
surface.
Replace pressure plate or flywheel.

Weakened engine mounting or loosened
installing bolt or nut.
Retighten or replace mounting.
Clutch Noise
Worn or broken release bearing.
Replace release bearing.

Worn input shaft bearing.
Replace input shaft bearing.

Cracked clutch disc.
Replace clutch disc.

Pressure plate and diaphragm spring
rattling.
Replace pressure plate.

Improper clutch cable adjustment.
Adjust clutch cable.
Grabbing Clutch
Clutch disc facing with oily contamination.
Replace clutch disc.

Excessively worn on clutch disc facing.
Replace clutch disc.

Rivet head showing out of facing.
Replace clutch disc.

Weakened clutch torsion spring.
Replace clutch disc.

CLUTCH 5C–5
DAEWOO M-150 BL2
CLUTCH PEDAL OPERATION
D103C301
Clutch pedal free travel
It is designed that there is no clutch pedal free travel.
Clutch pedal travel (A)

Pedal Travel

100–110 mm (3.9–4.3 in.)
Clearance between pedal and floor just
before clutch connection (B)
After starting the engine, check if the clearance between
pedal and floor is within specified range in condition of
idling, lifting, parking brake and drawing out clutch ped-
al.

Clearance Between Pedal and Floor
just Before Clutch Connection
30–40 mm
(1.2–1.6 in.)
Caution: During inspection, take care on sudden
departure.
CLUTCH CABLE ADJUSTMENT
D103C302
If clutch connection / disconnection is operated un-
smoothly, adjust the clutch cable by adjusting clutch
cable adjust nut.

5C –6 CLUTCH
DAEWOO M-150 BL2
INSTRUCTION REPAIR
ON–VEHICLE SERVICE
D13B5151
D103B516
PRESSURE PLATE, CLUTCH DISC
AND INPUT SHAFT BEARING
Tools Required
09917–58010 Input Shaft Bearing Remover
09924–17810 Flywheel Holder
09925–98210 Input Shaft Bearing Installer
DW110–021 Engine Fixture
DW210–010 Clutch Center Guide
Removal Procedure
1. Remove the transaxle from the vehicle. Refer to Sec-
tion 5B, Manual Transaxle.
2. Support the engine to normal position using the en-
gine fixture DW110–021.
Notice: The abnormal position of the engine may dam-
age to the related parts and interfere with them. You
must support the engine to normal position after remov-
ing the transaxle.
D13C5021
3. Remove the pressure plate and the clutch disc.

Fix the fly wheel using the fly wheel holder 09924–
17810.

Remove the pressure plate bolts (1).

Remove the pressure plate and the clutch disc (2).