DAEWOO NUBIRA 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 171
DAEWOO V–121 BL4
DIRECT CLUTCH
1. Seal Ring
2. Input Shaft Sub–assembly
3. O–Ring
4. Piston
5. O–Ring
6. Return Spring7. Snap Ring
8. Plate
9. Disc
10. Flange
11. Snap Ring

5A2 – 172IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Tools Required
DW240–020 Brake/Clutch Spring Compressor
DW240–040 Direct Clutch Adapter
Disassembly Procedure
WARNING : USE CAUTION WHEN CHECKING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
1. Install the direct clutch and thrust needle roller
bearing on the oil pump.
2. Using a dial indicator, measure the direct clutch
piston stroke while applying and releasing 392 kPa
(57 psi).of compressed air.
Piston stroke: 0.4
0.8 mm (0.016
0.031 in.)
If the stroke is non–standard, inspect the discs,
plates and flange.
3. Using a screwdriver, remove the snap ring.
4. Remove the flange, 2discs and 2 plates.
5. Place the brake/clutch spring compressor
DW240–020 and direct clutch adapter DW240–040
on the direct clutch return spring and compress.
6. Using a snap ring expander, remove the snap ring.
Notice : Stop the press when the piston return spring is
lowered to the place 1–2 mm (0.039–0.078 in.) from the
snap ring groove, preventing the piston return spring from
being deformed.
Notice : Do not expand the snap ring excessively.

AISIN AUTOMATIC TRANSAXLE 5A2 – 173
DAEWOO V–121 BL4
7. Remove the direct clutch return spring.
8. Install the direct clutch on the oil pump.
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
Notice : Blowing off the air may cause the piston’jump–
out.When removing the piston, hold it with your hand using
a waste cloth.
Notice : Take care not to splash ATF when air–blowing.
9. Apply 392 kPa (57 psi) of compressed air to the oil
pump to remove the direct clutch piston.
S When the piston can not be removed as it is
slanted, either blow the air again with the pro-
truding side pushed or remove the piston using
needle nose pliers with vinyl tape on the tip.
10. Using a small screwdriver, remove the O–ring from
the direct clutch piston.
11. Remove the O–ring from the input shaft.

5A2 – 174IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
12. Remove the 2 seal rings from the input shaft.
Notice : Do not expand the ring ends excessively.
Inspection Procedure
1. Check to see if the sliding surface of the disc, plate
and flange are worm or burnt. If necessary, replace
them.
S If the lining of the disc is peeling off or discol-
ored, or even if a part of the printed number is
defaced, replace all discs.
S Before assembling new discs, soak them in ATF
for at least 15 minutes.
2. Using vernier calipers, measure the free length of
the direct clutch return spring together with the
spring sheet.
S Standard free length: 36.04 mm (1.4189 in.)
3. Check that the check ball is free by shaking the di-
rect clutch piston.
4. Check that the valve does not leak by applying low–
pressure compressed air.

AISIN AUTOMATIC TRANSAXLE 5A2 – 175
DAEWOO V–121 BL4
Assembly Procedure
1. Install the 2 seal rings to the input shaft.
Notice : Do not expand the ring ends excessively.
2. Coat a new O–ring with ATF and install the O–ring
to the input shaft.
3. Coat a new O–ring with ATF and install the O–ring
to the direct clutch piston.
4. Coat the direct clutch piston with ATF, install it to
the direct clutch drum.
Notice : Be careful not to damage the lip seal of direct
clutch piston.

5A2 – 176IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
5. Install the direct clutch return spring.
6. Place brake/clutch spring compressor DW240–020
and direct clutch adapter DW240–040 on the return
spring and compress.
7. Using a snap ring expander, install the snap ring.
Notice : Stop the press when the piston return spring is
lowered to the place 1–2 mm (0.039–0.078 in.) from the
snap ring groove, preventing the piston return spring from
being deformed.
Notice : Do not expand the snap ring excessively.
8. Install the 2 plates, 2 discs and flange.
S Before installing the discs, coat them with
ATF.Install in order: P
D
P
D – F
(P = Plate, D = Disc, F = Flange)
9. Using a screwdriver, remove the snap ring.
10. Check that end gap of the snap ring is not aligned
with one of the cutouts.

AISIN AUTOMATIC TRANSAXLE 5A2 – 177
DAEWOO V–121 BL4
11. Install the direct clutch on the oil pump.
WARNING : USE CAUTION WHEN CHECKING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
12. Using a dial indicator, measure the direct clutch
piston stroke while applying and releasing 392 kPa
(57 psi) .of compressed air .
Piston stroke: 0.4
0.8 mm (0.016
0.031 in.)
S If the piston stroke is less than the limit of piston
stroke, parts may have been assembled incor-
rectly, so check and reassemble again.
S If the stroke is non–standard, select another
flange.
S There are 3 flanges in different thickness.
S Flange Thickness: mm (in.)
No
ThicknessNoThickness
13.0 (0.118)33.4 (0.134)
23.2 (0.126)

5A2 – 178IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
PLANETARY RING GEAR
1. Snap Ring
2. Planetary Ring Gear Flange3. Planetary Ring Gear

AISIN AUTOMATIC TRANSAXLE 5A2 – 179
DAEWOO V–121 BL4
Disassembly Procedure
1. Using a screwdriver, remove the snap ring.
2. Remove the planetary ring gear flange from the
planetary ring gear.
Assembly Procedure
1. Install a new planetary ring gear flange to the plan-
etary ring gear.
2. Using a screwdriver, install the snap ring.

5A2 – 180IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
ONE–WAY CLUTCH
1. Snap Ring
2. One–Way Clutch3. 2nd Brake Hub
4. Retainer