nut DAEWOO NUBIRA 2004 Service Repair Manual

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 199
DAEWOO V–121 BL4
3. Install the shift lever and the shift lever nut.
Tighten
Tighten the shift lever nut to 10 NSm (89 lb–in).
4. Connect the shift control cable and the retaining
clip.
5. Connect the park/neutral position switch electrical
connector.
6. Connect the negative battery cable.
OIL COOLER PIPES/HOSES
Removal Procedure
Important : Place a drip pan under the hoses to catch the
fluid that will run out of the lines.
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
4. Remove the oil cooler outlet pipe bolt from the right
lower side of the radiator.
5. Remove the oil cooler outlet pipe bracket bolt.
6. Remove the oil cooler outlet pipe bolt from the
transaxle side.
7. Remove the oil cooler outlet pipe assembly.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 205
DAEWOO V–121 BL4
7. Lower the vehicle.
8. Connect the transaxle wiring harness and the PNP
switch electrical connector.
9. Refill the transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
10. Connect the negative battery cable.
LEFT TRANSAXLE MOUNTING
BRACKET
Tools Required
DW110–060 Engine Support Fixture
Removal Procedure
1. Remove the battery. Refer to Section 1E, Engine
Electrical.
2. Install the engine support fixture DW110–060.
3. Remove the left transaxle mounting bolts.
4. Remove the left transaxle mount bracket cage bolts
and nut.
5. Remove the transaxle mounting bracket.

5A1 – 206IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Install the left transaxle mount bracket cage bolts
and nut.
Tighten
S Tighten the left transaxle mount bracket cage
bolt (a) to 110 NSm (81 lb–ft).
S Tighten the left transaxle mount bracket cage
bolt (b) to 65 NSm (48 lb–ft).
S Tighten the nut (c) to 65 NSm (48 lb–ft).
2. Install the left transaxle mounting bolts to 48 NSm
(35 lb–ft).
3. Remove the engine support fixture DW110–060.
4. Install the battery. Refer to Section 1E, Engine
Electrical.
TRANSAXLE ASSEMBLY
Tools Required
DW110–060 Engine Support Fixture
DW260–010 Transaxle Support Fixture
Removal Procedure
1. Disconnect the negative battery cable.
2. Position the select lever park position.
3. Remove the battery. Refer to Section 1E, Engine
Electrical.
4. Install the engine support fixture DW110–060.

5A1 – 208IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
10. Raise and suitably support the vehicle.
11. Drain the transaxle fluid.
12. Remove the oil cooler pipes from the transaxle. Re-
fer to ”Oil Cooler Pipes/Hoses” in this section.
13. Remove the drive axle. Refer to Section 3A, Auto-
matic Drive Axle.
14. Remove the starter motor. Refer to Section 1E, En-
gine Electrical.
15. Remove the torque converter bolts.
16. Support the transaxle.
17. Remove the rear transaxle mounting bracket bolts
(a) and damping block connection bolt and nut (b).
18. Support the transaxle assembly using the transaxle
support fixture DW260–010.

5A1 – 210IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
4. Install the rear transaxle mounting bracket bolts (a).
Tighten
Tighten the rear transaxle mounting bracket bolts (a)
to 62 NSm (45 lb–ft).
5. Install the damping block connection bolt and nut
(b).
Tighten
Tighten the damping block connection bolt and nut (b)
to 68 NSm (50 lb–ft).
6. Install the torque converter bolts.
7. Install the starter motor. Refer to Section 1E, En-
gine Electrical.
8. Install the drive axle. Refer to Section 3A, Automat-
ic Drive Axle.
9. Install the oil cooler pipes from the transaxle. Refer
to ”Oil Cooler Pipes/Hoses” in this section.
10. Lower the vehicle.
11. Install the left transaxle mounting bracket. Refer to
”Left Transaxle Mounting Bracket” in this section.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 225
DAEWOO V–121 BL4
BRAKE F, SLOTTED NUT
Tools Required
DW260–060 Brake F Split Stop Ring Remover
Disassembly and Assembly Procedure
1. Remove the side shaft. Refer to ”Side Shaft” in this
section.
2. Take OFF the disc set and the brake F inner disc
carrier.
3. Mount fixture and remove the brake F split stop
ring.
4. Remove the fixture and take off the cup spring.

5A2 – 4IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Drain Plug1713–
Control Cable Adjusting Nut8–71
Shift Control Lever Assembly Mounting Bolts8–71
Manual Valve Lever Shaft Nut12–106
Transmission Range (TR) Switch Bolts5.4–48
Input Speed Sensor Retaining Bolt5.4–48
Output Speed Sensor Retaining Bolt7.4–65
TCM Retaining Bolts5–44
Fluid Cooler Inlet Pipe Fitting Nut3526–
Fluid Cooler Inlet Pipe Bolt9–80
Inlet Pipe Union Bolt3526–
Fluid Cooler Rear Outlet Pipe Fitting Nut3526–
Fluid Cooler Rear Outlet Pipe Clip Bolt9–80
Front Outlet Pipe Union Bolt3526–
Lower Transaxle–to–Engine Retaining Bolts (a)7354–
Lower Transaxle–to–Engine Retaining Bolts (b)3123–
Lower Transaxle–to–Engine Retaining Bolts (c)2115–
Upper Transaxle–to–Engine Mounting Bolts7354–
Upper Transaxle Mounting Bracket Bolts6044–
Rear Mounting Bracket Bolts6044–
Damping Block Connection Nut and Bolt8059–
Torque Converter Bolts4543–
Screw Plugs7.4–65
Transaxle Apply Clamp Bolt5.4–48
Oil Reservoir Lock Plate Bolts5.4–48
Transaxle Case Plate Bolt9.8–87
Transaxle Housing Bolts2922–
Manual Detent Spring Bolt9.8–87
Parking Lock Pawl Bracket Bolts7.4–65
Planetary Ring Gear Nut (Standard)9.8–87
Planetary Ring Gear Nut (Maximum)2922–
Transaxle Rear Cover Bolts2518–
Oil Pump Bolts2518–
Valve Body Bolts11–97
Oil Strainer Bolts9.8–87
Oil Pan Bolts7–62
Unions2518–
Stator Shaft Bolts2518–
Shift Solenoid Valve Bolts11–97
Differential Case–to–Differential Ring Gear Bolt10275–

AISIN AUTOMATIC TRANSAXLE 5A2 – 5
DAEWOO V–121 BL4
SPECIAL TOOLS
SPECIAL TOOLS TABLE
DW260–021–02
Automatic
Transaxle
Overhaul
Fixture
DW240–020
Brake/Clutch
Spring Compressor
DW240–030
Forward Clutch
Adapter
DW240–040
Direct Clutch
Adapter
DW240–050
Overdrive
Brake Adapter
DW240–060–01
Brake Spring
Compressor
Bolt/Nut
DW240–060–02
Brake Spring
Compressor
Plate
DW240–070
1st/Reverse
Brake Adapter

5A2 – 6IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DW240–080
2nd Brake Adapter
DW240–090
Planetary Ring
Gear Remover
DW240–100
Counter Drive
Gear Installation
Adapter
DW260–041
Planetary Ring
Gear Nut
Removal/Installation
Socket (52mm)
DW260–031–01
Tranaxle Housing
Oil Seal Installer
DW260–031–02
Tranaxle Case
Oil Seal Installer
DW240–120
Measuring Terminal
DW240–130
Differential Preload
Adapter
DW260–013
Transaxle Support
Fixture
DW240–140
Transaxle Housing
Side Bearing
Outer Race
Adapter

AISIN AUTOMATIC TRANSAXLE 5A2 – 17
DAEWOO V–121 BL4
COMPONENT LOCATOR
SHIFT SELECT CONTROL
1. Select Control Lever Assembly
2. Bolt
3. Nut
4. Select Control Cable5. Clamp
6. E–ring
7. Cable Fastener
8. Bolt