DAEWOO NUBIRA 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 101
DAEWOO V–121 BL4
Installation Procedure
1. Install the shift control lever assembly and mount-
ing bolts and nuts.
Tighten
Tighten the shift control lever assembly mounting
bolts and nuts to 8 NSm (71 Ib–in).
2. Connect the control cable to the shift control lever
assembly.
3. Tighten the control cable adjusting nut.
Tighten
Tighten the control cable adjusting nut to 8 NSm (71
Ib–in).
4. Connect the harness connector.
5. Adjust the control cable. Refer to ”Control Cable
Adjustment” in this section.
6. Install the floor console. Refer to Section 9G, Interi-
or Trim.
7. Connect the negative battery cable.
TRANSMISSION RANGE (TR)
SWITCH
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the Transmission Range (TR) switch
electrical connector from the wiring harness.

5A2 – 102IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
3. Remove the E–ring.
4. Disconnect the shift control cable from the TR
switch lever.
5. Remove the retaining nut and then remove the
washer and the control lever.
6. Using a driver, unstake the lock washer and re-
move the nut.
Installation Procedure
1. Install the Transmission Range (TR) switch onto the
manual valve lever shaft and temporarily install the
2 adjusting bolts.
2. Install the new lock washer and nuts.
Tighten
Tighten the nuts to 12 NSm (106 Ib–in).
3. Temporarily install the control lever.
4. Turn the lever counterclockwise until it stops, then
turn it clockwise 2 notches.
5. Remove the control lever.

AISIN AUTOMATIC TRANSAXLE 5A2 – 103
DAEWOO V–121 BL4
6. Aligh the groove with the neutral basic line, then
install the 2 bolts.
Tighten
Tighten the 2 bolts to 5.4 NSm (48 Ib–in).
7. Using a screw driver, stake the nut with the lock
washer.
8. Install the control lever, washer and nut.
Tighten
Tighten the nut to 12 NSm (106 Ib–in).
9. Connect the control cable to TR switch.
10. Connect the TR switch electrical connector.
11. Adjust the control cable. Refer to ”Control Cable
Adjustment” in this section.
12. Install the control cable adjusting nut.
Tighten
Tighten the control cable adjusting nut to 8 NSm (71
Ib–in).
13. Connect the negative battery cable.

5A2 – 104IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
SHIFT CONTROL CABLE
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the floor console. Refer to Section 9G,
Interior Trim.
3. Remove the cable adjusting nut.
4. Disconnect the shift control cable from the shift
control lever assembly.
5. Remove the shift control cable retaining E–ring.
6. Disconnect the shift control cable from the TR
switch.
7. Remove the E–ring from the shift control cable
bracket and disconnect the shift control cable.
8. Disconnect the shift control cable from the shift
control cable fastener.
9. Remove the shift control cable from the vehicle.
Installation Procedure
1. Install the shift control cable to the vehicle.
2. Connect the shift control cable to the shift control
cable fastener.
3. Install the E–ring to the shift control cable bracket
and connect the shift control cable.

AISIN AUTOMATIC TRANSAXLE 5A2 – 105
DAEWOO V–121 BL4
4. Connect the shift control cable to the TR switch.
5. Install the shift control cable retaining E–ring.
6. Connect the shift control cable to the shift control
lever assembly.
7. Install the cable adjusting nut.
Tighten
Tighten the cable adjusting nut to 8 NSm (71 Ib–in).
8. Install the trim panel to the floor console. Refer to
Section 9G, Interior Trim.
9. Connect the negative battery cable.
SHIFT SELECT COVER
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the floor console. Refer to Section 9G,
Interior Trim.
3. Remove the shift select lever knob.
4. Disconnect the connectors.
5. Remove the shift select cover from the shift select
housing.

5A2 – 106IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Connect the connectors to the shift select cover.
2. Install the shift select cover to the housing.
3. Install the shift select lever knob.
4. Install the floor console. Refer to Section 9G, Interi-
or Trim.
5. Connect the negative battery cable.
INPUT SHAFT SPEED (ISS) SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the input shaft speed (ISS) sensor elec-
trical connector.
3. Remove the ISS sensor retaining bolt.
4. Remove the ISS sensor from the transaxle.

AISIN AUTOMATIC TRANSAXLE 5A2 – 107
DAEWOO V–121 BL4
Installation Procedure
Notice : Lubricate the O–ring with ISU DEXRON III.
1. Install a new O–ring on the ISS sensor.
2. Install the ISS sensor and retaining bolt into the
transaxle case.
Tighten
Tighten the ISS sensor retaining bolt to 5.4 NSm (48
Ib–in).
3. Connect the ISS sensor electrical connector.
4. Connect the negative battery cable.
OUTPUT SHAFT SPEED (OSS)
SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the output shaft speed (OSS) sensor
electrical connector.
3. Remove the OSS sensor retaining bolt.
4. Remove the OSS sensor from the transaxle.

5A2 – 108IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
Notice : Lubricate the O–ring with ISU DEXRON III.
1. Install a new O–ring on the output shaft speed
(OSS) sensor.
2. Install the OSS sensor and retaining bolt into the
transaxle.
Tighten
Tighten the OSS sensor retaining bolt to 7.4 NSm (65
Ib–in).
3. Connect the OSS sensor electrical connector.
4. Connect the negative battery cable.
TRANSMISSION CONTROL MODULE
(TCM)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the transmission control module (TCM)
electrical connector.
3. Remove the TCM retaining bolts.
4. Remove the TCM.

AISIN AUTOMATIC TRANSAXLE 5A2 – 109
DAEWOO V–121 BL4
Installation Procedure
1. Connect the negative battery cable.
2. Install the TCM and retaining bolts.
Tighten
Tighten the TCM retaining bolts to 5 NSm (44 Ib–in).
3. Connect the TCM electrical connector.
4. Connect the negative battery cable.
FLUID COOLER INLET PIPES AND
HOSES
Removal Procedure
1. Raise and support the vehicle.
2. Drain the transaxle fluid.
3. Remove the clip from the hose, then disconnect the
hose from the fluid cooler inlet pipe.
4. Remove the inlet pipe union bolt from the radiator.
5. Remove the fluid cooler inlet pipe bolt from the
transaxle.
6. Remove the inlet pipe fitting nut from the transaxle.
7. Remove the fluid cooler inlet pipe and hoses.

5A2 – 110IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Install the fluid cooler inlet pipe fitting nut into the
transaxle.
Tighten
Tighten the fluid cooler inlet pipe fitting nut to 35 NSm
(26 Ib–ft).
2. Install the fluid cooler inlet pipe bolt into the trans-
axle.
Tighten
Tighten the fluid cooler inlet pipe bolt to 9 NSm (80 Ib–
in).
3. Install the inlet pipe union bolt into the radiator.
Tighten
Tighten the inlet pipe union bolt to 35 NSm (26 Ib–ft).
4. Connect the hose to inlet pipe and install the clip
into the hose.
5. Lower the vehicle.
6. Fill the transaxle with the fluid.
FLUID COOLER OUTLET PIPE AND
HOSES
Removal Procedure
1. Drain the transaxle fluid.
2. Remove the front outlet pipe union bolt from the
radiator.
3. Remove the clip from the hose.
4. Remove the rear outlet pipe clip bolt from the trans-
axle.
5. Remove the rear outlet pipe fitting nut from the
transaxle.
6. Remove the fluid cooler outlet pipe and hoses.