DAEWOO MATIZ 2003 Service Repair Manual

5B–6 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
GEAR SHIFT FORK
D13B4021
1 Shift and Select Shaft
2 Shift Interlock Bolt
3 Shift Lever
4 Select Lever
5 Shift and Select Shaft Boot
6 Gearshift Control Case
7 Shift Guide Bolt
8 Gearshift Control Case Guide Plate
9 Gearshift Control Case Gasket
10 Low Speed Shift Fork
11 Low Speed Shift Shaft
12 Low Speed Shift Shaft Spring/Ball
13 Low Speed Shift York14 High Speed Shift York
15 High Speed Shaft Spring/Ball
16 High Speed Shift Shaft
17 High Speed Shift Fork
18 Reverse Shift Arm
19 5th/Reverse Shift Ball
20 5th/Reverse Shift Shaft Spring/Ball
21 Reverse Shift Shaft Guide Spring/Ball
22 5th/Reverse Shift Shaft
23 5th/Reverse Shift York
24 5th/Shift Fork Guide Ball
25 5th/Shift Fork
26 Reverse Shift Lever

FIVE-SPEED MANUAL TRANSAXLE 5B–7
DAEWOO M-150 BL2
DIFFERENTIAL AND CASE
D13B4041
1 Speedometer Driven Gear
2 Oil Level Plug
3 Case Cap O–ring(Left)
4 Case Cap(Left)
5 Back Up Light Switch
6 Transaxle Case(Right)
7 Oil Plate
8 Transaxle Case(Left)
9 Oil Drain Plug
10 Oil Gutter
11 Side Cover Plate
12 Side Cover
13 Differential Ring Gear14 Differential Oil Seal(Left)
15 Differential Bearing(Left)
16 Differential Case
17 Speedometer Drive Gear
18 Differential Bearing(Right)
19 Differential Oil Seal(Right)
20 Differential Pinion Gear Shaft Pin
21 Differential Side Gear Adjust Shim
22 Differential Side Gear
23 Differential Pinion Gear Shaft
24 Differential Pinion Gear
25 Differential Pinion Gear Washer

5B–8 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURE
GENERAL DIAGNOSIS
ConditionProbable CauseCorrection
Gear Slipping Out of Mesh
Worn shift fork.
Replace shift fork.

Worn synchronizer sleeve or gear.
Replace sleeve or gear.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Weakened or damaged location
spring.
Replace spring.

Loose or damaged synchronizer
spring.
Replace synchronizer spring.

Excessive back-lash of gear.
Adjust back-lash of gear.
Gear Catching
Bent or distorted shift shaft or shift
fork.
Replace shift shaft or shift fork.

Weakened or damaged
synchronizer spring.
Replace spring.
Hard Shifting
Worn synchronizer ring.
Replace synchronizer ring.

Worn synchronizer sleeve or gear.
Replace sleeve or gear.

Bent or distorted shift shaft.
Replace shift shaft.

Excessive free travel of all gears
in axial direction.
Replace gear.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Poor adjustment of clutch cable.
Adjust clutch cable.

Distorted or broken clutch disc.
Replace clutch disc.

Damaged pressure plate.
Replace pressure plate.
Noise in the Neutral Gear
Insufficient lubricant.
Supply lubricant.

Worn input shaft gear.
Replace gear.

Worn bearings on the input shaft
gears.
Replace bearing.

Worn clutch release bearing.
Replace clutch release bearing.
Noise in the All Gears
Insufficient lubricant.
Supply lubricant.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Worn input shaft or counter shaft
gear.
Replace gear.

Worn or damaged synchronizer
ring.
Replace synchronizer ring.

Worn or damaged synchronizer
sleeve.
Replace synchronizer sleeve.

Worn differential gear or bearing.
Replace gear or bearing.
Noise in the Peculiar Gear
Worn or damaged synchronizer
ring in the peculiar gear.
Replace synchronizer ring.

Worn or damaged gear in the
peculiar gear.
Replace gear.

Worn or damaged bearing in the
peculiar gear.
Replace bearing.
Leak of Lubricant
Damaged gasket, oil seal or
O-ring.
Replace gasket, oil seal or O-ing.

FIVE-SPEED MANUAL TRANSAXLE 5B–9
DAEWOO M-150 BL2
CHECKING FLUID LEVEL
Check for a leak in the area of transaxle case and seal-
ing and then check fluid level and condition after remov-
ing oil level plug.
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Remove the oil level plug and check the fluid level.
4. The fluid should slightly flow out from the oil level plug
hole.
5. If the level is low, add the recommended fluid through
the oil level plug hole until the fluid begins to run out.
6. If the fluid is contaminated or discolored, replace it
with the recommended fluid.
7. Reinstall the oil level plug and tighten it securely.
D103B301
CHANGING FLUID
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Drain the fluid after removing the drain plug.
4. Reinstall the drain plug and tighten it securely after
coating sealant.
5. Remove the oil level plug and replenish the fluid until
it begins to run out.
a. Oil drain plug.
b. Oil level plug.
6. Reinstall the oil level plug and tighten it securely.Fluid Specification
75W-85(GL-4)
Fluid Capacity2.1L(2.21qt)
Service intervalRefer to Owner’s Manual
CHECKING TRANSAXLE NOISE
Many noises that appear to come from the transaxle
may actually originate with other sources such as tires,
road surfaces, wheel bearings, or engine and exhaust
system.
Identify the cause of any noise before attempting to re-
pair the clutch, the transaxle, or their related linkages.
To verify suspected transaxle noises,
1. Select a smooth, level asphalt road to reduce tyre
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lubri-
cants thoroughly.
3. Record the speed and the gear range of the transaxle
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 oper-
ates in.

Drive – Under a light acceleration or a heavy pull.

Float – Maintaining a constant speed with a light
throttle on a level road.

Coast – With the transaxle in gear and the throttle
partly or fully closed.

All of the above.
CHECKING 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 di-
minish 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.

5B–10 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
REPAIR INSTRUCTION
ON–VEHICLE SERVICE
D103B501
MANUAL TRANSAXLE ASSEMBLY
Tools Required
DW110–021 Engine Support Fixture
DW220–031 Transaxle Remove/Install Support
Removal Procedure
1. Remove the air cleaner assembly. Refer to Section
1B, SOHC Engine Mechanical.
2. Remove the battery and battery tray. Refer to Section
1E, Engine Electrical.
3. Disconnect the select and the shift cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and the shift cable (3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.
D103B502
4. Remove the engine wiring harness bending strap.
5. Disconnect the ground wire and the backup lamp
switch connector.

Remove the ground wire bolt (1).

Disconnect the ground wire (2).

Disconnect the backup lamp switch connector (3).

FIVE-SPEED MANUAL TRANSAXLE 5B–11
DAEWOO M-150 BL2
D13B5031
6. Disconnect the radiator lower hose.

Remove the bolts (1).

Disconnect the radiator lower hose (2).
7. Remove crankshaft position (CKP) sensor.

Remove the bolt (3).

Disconnect the CKP sensor connector

Remove the CKP sensor.
D103B507
8. Disconnect the speedometer cable.

Loosen the nut (1).

Disconnect the cable (2).
9. Remove the vehicle speed sensor (VSS) if
equipped.

Disconnect VSS connector.

Remove the VSS.
D102E502
10. Remove the starter motor.

Remove upper two bolts that securing starter mo-
tor to transaxle.
D13B5041
11. Fix the engine assembly.

Remove the cowl panel weatherstrip.

Position the engine support fixture DW110–021
on the cowl panel and the front upper panel.

Tighten the engine fixture joint with a bolt after re-
moving exhaust manifold bolt (No.4).

5B–12 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B510
12. Remove the transaxle upper bolts.
a. Exhaust manifold side bolt.
b. Thermostat housing side bolt.
D103B505
13. Remove the transaxle under cover.

Remove the bolts (1).

Remove the transaxle under cover (2).
14. Remove the front tires and wheels.
D103B506
15. Drain the transaxle fluid.

Remove the drain plug and drain the fluid.
16. Disconnect the clutch cable.

Remove the cable adjust nut (1).

Disconnect the cable from the wire clip (2).

Disconnect the cable from the transaxle mount
hole (3).
D103B509
17. Remove the front under longitudinal frames and sta-
bilizer. Refer to Section 2C, Front Suspension.
18. Remove the drive axle (only transaxle side). Refer
to Section 3B, Manual Transaxle Drive Axle.
19. Remove the clutch housing lower plate.

Remove the bolts (1).

Remove the lower plate (2).

FIVE-SPEED MANUAL TRANSAXLE 5B–13
DAEWOO M-150 BL2
D12B5731
20. Remove the front exhaust pipe.

Remove the front exhaust pipe nuts (exhaust
manifold side) (1).

Remove the gasket and separate exhaust man-
ifold pipe (2).

Make free the front exhaust pipe.
D13B5111
21. Support the transaxle with the transaxle remove/
install support DW220–030N.

Position the support on the jack (a).

Support the transaxle case and mount using a
jack and the transaxle remove/install support.
D103B512
22. Remove the transaxle lower bolt and nut.
a. Lower bolt.
b. Lower nut.
D13B5131
23. Remove the transaxle mount bolts.

5B–14 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B5141
24. Position the manual transaxle assembly in tilting.

To remove the manual transaxle side cover with-
out the interference with the front under longitudi-
nal panel (Left), tilt the engine/manual transaxle by
loosening the engine support fixture DW110– 021
joint with the wrench.
D13B5151
25. Remove the manual transaxle assembly.

Lower the transaxle assembly slowly by adjusting
jack.
a. Jack.
b. Transaxle assembly.

Tilt the transaxle assembly by adjusting jack.

Remove the transaxle assembly by pulling and
lowering it slowly.
D103B516
26. Support the engine to normal position using the en-
gine support fixture DW110–021.
Notice: The abnormal position of the engine may dam-
age to the related parts or interfere with them. You have
to support the engine to normal position when removing
the transaxle.
Important: If it is impossible to use the special tool, sup-
port the engine to normal position with the auto jack.
D13B5171
Installation Procedure
1. Install in the reverse order of removal.
2. Install the transaxle mounting bolts.
Tighten
Tighten the transaxle mounting bolts (body side) to
45–55 Nm (33–41 lb-ft).

FIVE-SPEED MANUAL TRANSAXLE 5B–15
DAEWOO M-150 BL2
D13B518A
3. Install the transaxle lower bolt, nut.
Tighten
Tighten the bolt and nut to 55–65 Nm (41–48 lb-ft).
a. Lower bolt.
b. Lower nut.
D13B5472
4. Tighten the front exhaust pipe nuts.
Tighten

Tighten the front exhaust pipe nuts (exhaust man-
ifold side) to 25–35 Nm (18–25 lb-ft).
D13B519A
5. Install the transaxle upper bolts.
Tighten
Tighten the bolts to 55–65 Nm (41–48 lb-ft).
a. Exhaust manifold side bolt.
b. Thermostat housing side bolt.
D13B548A
6. Install the starter motor.
Tighten
Tighten the starter motor bolts to 18–28 Nm (13–21
lb-ft).
7. Connect all electric connectors.