DAEWOO MATIZ 2003 Service Repair Manual

3B –8 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
35–55 N
m
D13B521A
11. Install the transaxle under cover.
Tighten
Tighten the transaxle under cover bolts to 35–55
N
m (25–41 lb-ft)

MANUAL TRANSAXLE DRIVE AXLE 3B–9
DAEWOO M-150 BL2
UNIT REPAIR
D104B701
INNER JOINT (TRANSAXLE SIDE)
Tool Required
J–35566 Boot Clamp Pliers
Disassembly Procedure
1. Remove the drive axle. Refer to “Drive Axle Assem-
bly” in this section.
2. Remove the clamps on the joint boot.
Remove the boot clamp (large) using the boot
clamp pliers J–35566 (1).
Remove the boot clamp (small) (2).
D104B702
3. Remove the joint housing from boot.
a. Boot.
b. Joint housing.
D104B703
4. Degrease the joint assembly.
5. Remove the tripot joint.
Remove the circlip (1).
Remove the tripot joint (2).

3B –10 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
D104B704
6. Remove the drive axle shaft boot.
D104B705
Assembly Procedure
1. Install in the reverse order of removal.
2. Fill the joint housing with recommended grease when
installing.
Capacity 90–100 g (3.2–3.5 ounces)
Notice: Always use the recommended grease. If not,
joint and boot can be damaged.
Important: Always use new clamps.
Inspection Procedure
1. Inspect the operation of joint.
2. Inspect for a leaking boot through the clamp side.
D104B706
OUTER JOINT (WHEEL SIDE)
Disassembly Procedure
1. Remove the drive axle. Refer to “Drive Axle Assem-
bly” in this section.
2. Remove the clamps on the joint boot.
Remove the boot clamps (1,2).
D104B707
3. Degrease the joint assembly.
4. Remove the joint assembly.
Widen the circlip (1).
Remove the joint assembly while widening the cir-
clip (2).

MANUAL TRANSAXLE DRIVE AXLE 3B–11
DAEWOO M-150 BL2
D104B704
5. Remove the drive axle shaft boot.
D104B708
Assembly Procedure
1. Install in the reverse order of removal.
2. Install the joint assembly.
Pre–install the joint assembly by pushing to the
drive axle shaft to widen the circlip.
Keep the circlip widened (1).
Push the joint assembly to the drive axle shaft (2).
D104B709
3. Fill the joint housing with recommended grease when
installing.
Capacity 80–90 g (2.8–3.2 ounces)
Notice: Always use the recommended grease. If not,
joint and boot can be damaged.
Important: Always use new clamps.
D104B710
Inspection Procedure
1. Inspect the operation of joint.
2. Inspect for a leaking boot through the clamp side.
Important: Do not disassemble the outer joint assem-
bly. Parts are match fit and can not be serviced sepa-
rately. Improper reassembly will adversely affect both
performance and safety.

3B –12 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Description

Unit

Standard

Limit
Inner

–Tripot Joint

– Type
Outer

–Rzeppa Joint

–
Right

mm (in.)553.5(21.79)

– Length
Left

mm (in.)386.5(15.22)

– Drive AxleShaft Diameter

mm (in.)22 (0.87)

–


Inner

g (ounce)90 – 100
(3.2 – 3.5)

–


Grease Capacity
Outer

g (ounce)80 – 90
(2.8 – 3.2)
–
FASTENER TIGHTENING SPECIFICATIONS
Application N
m Lb-Ft Lb-In
Control Arm Ball Joint Bolt 50 – 70 36 – 52 –
Tie Rod End Joint castellated Nut 30 – 55 21 – 41 –
Stabilizer Bar Bolt 33 – 53 24 – 39 –
Stabilizer Bar Castellated Nut40 – 5030 – 36–
Drive Axle Shaft Nut 210 155 –
Wheel Nut 90 – 11 0 66 – 81 –
Transaxle Under Cover Bolt35 – 5525 – 41–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–

MANUAL TRANSAXLE DRIVE AXLE 3B–13
DAEWOO M-150 BL2
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
D104B101
KM–507–B
Tie Rod End
Joint Remover
D105B101
J–35566
Boot Clamp Pliers

DAEWOO M-150 BL2
SECTION 4A
HYDRAULIC BRAKES
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 4A-2. . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A-2. . . . . . . . . . . . . . . . . . .
Component Locator 4A-3. . . . . . . . . . . . . . . . . . . . . . . .
Brake System (Non-ABS) 4A-3. . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4A-4. . . . .
Brake System Testing 4A-4. . . . . . . . . . . . . . . . . . . . . .
Brake Hose Inspection 4A-4. . . . . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A-5. . . . . . . . . . . . . . . . . . .
Brake System Fault 4A-5. . . . . . . . . . . . . . . . . . . . . . . .
Manual Bleeding the Brakes 4A-6. . . . . . . . . . . . . . . .
Pedal Travel Check 4A-6. . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Free Play Inspection 4A-7. . . . . . . . . . . Repair Instructions 4A-8. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 4A-8. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose (Front) 4A-8. . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose (Rear) 4A-9. . . . . . . . . . . . . . . . . . . . . . . .
Stoplamp Switch 4A-9. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal 4A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 4A-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4A-13. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4A-13. . . . . . . . . .
Schematic and Routing Diagrams 4A-14. . . . . . . . . .
Brake Lamp Warning Circuit 4A-14. . . . . . . . . . . . . . .
Stoplamp Switch Circuit 4A-14. . . . . . . . . . . . . . . . . . .

4A – 2 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
WARNING LAMP OPERATION
This brake system uses a BRAKE warning lamp located
in the instrument panel cluster. When the ignition switch
is in the III position, the BRAKE warning lamp should il-
luminate. It should go off when the ignition switch return
to II position. The following conditions will activate the
BRAKE warning lamp.

The lamp should be on whenever the parking brake
applied and the ignition switch is in the II position.

A low fluid level in the master cylinder will turn the
BRAKE warning lamp on.
D17A007A

HYDRAULIC BRAKES 4A–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
BRAKE SYSTEM (NON–ABS)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
MAB4A001
1. Power Booster
2. Power Booster Boot
3. Cotter Pin
4. Clevis
5. Clevis Pin
6. Packing
7. Spacer
8. Master Cylinder Assembly
9. Fluid Reservoir Assembly
10. Reservoir Cap
11. Reservoir
12. Grommet Seal
13. Master Cylinder
14. Proportioning Valve
15. Stoplamp Switch
16. Brake Pedal Assembly
17. Clutch Pedal Spring18. Pedal Bracket Assembly
19. Clutch Pedal Pad
20. Clutch Pedal
21. Cushion
22. Bushing
23. Retaining Ring
24. Spring
25. Brake Pedal Pad
26. Brake Pedal
27. Brake Pedal Spring
28. Accelator Pedal Pad
29. Accelator Pedal
30. Rear Drum Brake Hose
31. E Ring
32. Front Disc Brake Hose
33. Brake Hose Coupling Bolt
34. Plain Washer

4A –4 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DIAGNOSITIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily
braked, but turning, wheels will stop the vehicle in less
distance than locked brakes. More tire-to-road friction is
present with a heavily braked, turning tire than with a
sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:

Tires having unequal contact and grip of the road will
cause unequal braking. Tires must be equally in-
flated, and the tread pattern of the right and the left
tires must be approximately equal.

Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.

Misalignment of the wheels, particularly conditions of
excessive camber and caster, will cause the brakes
to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and the
shift lever in NEUTRAL. If the pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking. Perform a visual check to confirm any sus-
pected leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an
abnormally low level indicates a leak in the system. The
hydraulic system may be leaking either internally or ex-
ternally. Refer to the procedure below to check the mas-
ter cylinder. Also, the system may appear to pass this
test while still having a slight leak. If the fluid level is nor-
mal, check the vacuum booster pushrod length. If an in-
correct pushrod length is found, adjust or replace the
rod.Check the master cylinder using the following proce-
dure:

Check for a cracked master cylinder casting or brake
fluid leaking around the master cylinder. Leaks are in-
dicated only if there is at least one drop of fluid. A
damp condition is not abnormal.

Check for a binding pedal linkage and for an incorrect
pushrod length. If both of these parts are in satisfac-
tory condition, disassemble the master cylinder and
check for an elongated or swollen primary cylinder or
piston seals. If swollen seals are found, substandard
or contaminated brake fluid should be suspected. If
contaminated brake fluid is found, all the components
should be disassembled and cleaned, and all the rub-
ber components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, then the rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston seals on the
drum brake wheels.
If rubber deterioration is evident, disassemble all the hy-
draulic parts and wash the parts with alcohol. Dry these
parts with compressed air before reassembly to keep al-
cohol out of the system. Replace all the rubber parts in
the system, including the hoses. Also, when working on
the brake mechanisms, check for fluid on the linings. If
excessive fluid is found, replace the linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush the
master cylinder with brake fluid, refill the master cylin-
der, and bleed the system. Refer to “Manual Bleeding
the Brakes” in this section.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of the
outer cover, and for leaks or blisters. Inspect the hoses
for proper routing and mounting. A brake hose that rubs
on a suspension component will wear and eventually
fail. A light and a mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as neces-
sary.