DAEWOO MATIZ 2003 Service Repair Manual

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).

FIVE-SPEED MANUAL TRANSAXLE 5B–37
DAEWOO M-150 BL2
D103B747
3. Remove the input shaft fifth gear spacer, the left side
bearing and the fourth gear.

Position the fourth gear to the gear,bearing remov-
er DW09921–57810.

Remove the following parts.
a. Fifth gear spacer.
b. Left side bearing.
c. Fourth gear
D103B748
4. Remove the fourth gear bearing.
5. Remove the fourth gear synchronizer ring and wave
spring.
D103B749
6. Remove the third–fourth synchronizer circlip.
D103B750
7. Remove the third–fourth synchronizer hub assembly,
the third gear 1 synchronizer ring.

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

Remove the following parts.
a. Third–fourth synchronizer hub assembly.
b. Third gear and synchronizer ring.

5B–38 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B751
8. Disassemble the third–fourth synchronizer hub as-
sembly.

Remove the hub (1).

Remove the synchronizer sleeve and the key (2).

Remove the synchronizer springs (3).
D103B752
9. Remove the input shaft third gear bearing (1).
D103B753
Synchronizer Assembly Inspection
1. Inspecting wear of cone area.

After matching synchronizer ring to gear, measure
as shown in figure. Replace if it is below limit.
Unit : mm (in.)
Clearance Between Standard Limit Clearance Between
Gear and Ring
1.0 (0.039)0.5 (0.020)
D103B754
2. Inspecting cone contact condition.

When synchronizer mechanism is abnormal in op-
eration, connection between ring inner surface and
gear cone area is considered to be partially defec-
tive in spite of correct clearance between gear and
ring. Therefore, cone area and ring inner surface
shall be inspected. In this case, ring inner surface
shall be glossy. Black area is abnormal and if in-
spection is difficult, check after applying red lead.
Cone area can be worn in wave form.

FIVE-SPEED MANUAL TRANSAXLE 5B–39
DAEWOO M-150 BL2
D103B755
3. Inspecting key slot width of synchronizer ring.

Measure key slot width of synchronizer ring. Re-
place if it exceeds limit.
Unit : mm (in.)
Key Slot Width Standard Limit
1st gear8.2 (0.323)8.6 (0.339)
2nd, 3rd, 4th gear9.6 (0.378)10.0 (0.394)
5th gear9.4 (0.370)9.8 (0.386)
D103B756
4. Inspecting wear of synchronizer ring.

Check for worn or damaged synchronizer ring
teeth. Replace it if necessary.
D103B757
5. Inspecting synchronizer key and spring.

Check for worn synchronizer key (1).

Check for weak, damaged or broken spring (2).
D103B758
Assembly Procedure
1. Install the third gear bearing, the third gear / synchro-
nizer ring.
a. Third gear / synchronizer ring.
b. Third gear bearing.
Important: Coat the inner parts; gear, bearing, oil seal
etc. with gear fluid.

5B–40 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B759
2. Assemble the third–fourth synchronizer hub assem-
bly.

Install the synchronizer springs to the hub.

Install the synchronizer key to the hub.
Important: In case of assembling the synchronizer
sleeve and the hub, let A=B.

Install the hub to the sleeve.
a. Sleeve.
b. Hub.
D103B760
3. Install the third–fourth synchronizer hub assembly.

Insert the hub assembly into the input shaft (1).
Important: Position the longer flange of hub toward the
third gear and match the key and the ring groove.

Install the hub assembly using a hammer and the
gear, bearing installer DW09940–53111.
D13B761A
Notice: When installing gear, bearing and hub assem-
bly, install them slowly using the gear, bearing installer
DW09940–53111 and a hammer. If overpressed, the
gear teeth may be damaged.
D103B749
4. Install the third–fourth synchronizer circlip.
5. Install the fourth synchronizer ring and wave spring.
Important: Match the ring groove to the key of hub.

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–42 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
Disassembly Procedure
1. Remove the gear unit. Refer to “Gear Unit” in this
section.
2. Remove the counter shaft right side bearing.
D103B766
3. Remove the counter shaft left side bearing and the
fourth gear.

Position the fourth gear to the gear, bearing remov-
er DW09921–57810.

Remove the following parts by pressing.
a. Counter shaft left side bearing.
b. Fourth gear.
D103B767
4. Remove the counter shaft third–fourth gear spacer.
5. Remove the counter shaft third gear and second gear.

Position the second gear to the gear, bearing re-
mover DW09921–57810.

Remove the following parts by pressing
a. Third gear.
b. Second gear.
D103B768
6. Remove the counter shaft second gear bearing.
7. Remove the second gear synchronizer ring.
8. Remove the first–second gear synchronizer circlip.

FIVE-SPEED MANUAL TRANSAXLE 5B–43
DAEWOO M-150 BL2
D103B769
9. Remove the counter shaft first–second gear syn-
chronizer hub assembly, the first gear / the first gear
synchronizer ring.

Position the first gear to the gear, bearing remov-
er DW09921–57810.

Remove the following parts by pressing.
a. Synchronizer hub assembly.
b. First gear / First gear synchronizer ring.

Remove the first gear synchronizer ring from the
first gear.
D103B770
10. Disassemble the first–second gear synchronizer
hub assembly.

Push the hub from the hub assembly (1).

Disassemble the synchronizer sleeve and key
(2).

Disassemble the synchronizer springs (3).
D103B771
11. Remove the counter shaft first gear bearing.
D103B772
Synchronizer Hub and Sleeve Inspection

Check the sleeve for improper operation after assem-
bling the hub and the sleeve.

Check the wear of hub and sleeve.

Replace synchronizer hub or sleeve if necessary.

5B–44 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B773
Assembly Procedure
1. Install the related counter shaft first gear.

Install the first gear bearing (1).

Install the first gear (2).

Install the first gear synchronizer ring (3)
Important: Coat the inner parts; gear, bearing and oil
seal etc. with gear fluid.
Important: Be careful there is the difference of key
groove width between the first synchronizer ring and the
second synchronizer ring.
D103B774A
Unit : mm (in.)




First synchronizer ring (A)
: 8.2 (0.323)


Key Groove Width
Second synchronizer ring
(B) : 9.6 (0.378)
D103B775
2. Assemble the first–second synchronizer hub assem-
bly.

Install the synchronizer springs to hub.

Install the synchronizer keys to hub.
Important: Let (A)=(B) when installing the keys.

Install the hub to the sleeve.
a. Sleeve.
b. Hub.
D103B776
3. Install the first–second synchronizer hub assembly.

Insert the hub assembly into the counter shaft us-
ing the gear, bearing installer DW09940–53111,
the gear bearing remover/installer KM466–A and a
hammer (1).
Important: Position the synchronizer key to the first
gear synchronizer ring groove.

FIVE-SPEED MANUAL TRANSAXLE 5B–45
DAEWOO M-150 BL2
D103B768
4. Install the second synchronizer ring.
Important: Position the second synchronizer ring groove
to the synchronizer hub key.
5. Install the first–second gear synchronizer circlip.
D103B777
6. Install the related counter shaft second gear.

Install the second gear bearing (1).

Install the second gear (2).
D103B778
7. Install the counter shaft third gear and the third–fourth
gear spacer.

Insert the third gear and the third–fourth gear
spacer into the counter shaft.

Install the following parts using the gear, bearing
installer DW09913–80112 and a hammer.
a. Third–fourth gear spacer.
b. Third gear.
D103B779
8. Install the counter shaft fourth gear.

Install the fourth gear to the counter shaft using the
gear, bearing installer DW09925–98221 and a
hammer (1).