nut DAEWOO NUBIRA 2004 Service Repair Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 137
DAEWOO V–121 BL4
MAJOR COMPONENT ASSEMBLY
Tools Required
DW240–020 Brake/Clutch Spring Compressor
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
DW240–100 Counter Drive Gear Installation Adapter
DW240–130 Differential Preload Adapter
DW260–031–01 Transaxle Housing Oil Seal Installer
DW260–031–02 Transaxle Case Oil Seal Installer
DW260–041 Planetary Ring Gear Nut Removal/Installa-
tion Socket
DW240–160 Transaxle Case Outer Tapered Roller Bear-
ing Race Adapter
DW240–140 Transaxle Housing Side Bearing Outer Race
Adapter
DW240–170 Adapter Handle
Assembly Procedure
1. Install 4 new O–rings to the 4 screw plugs.
2. Install the 4 screw plugs with the O–rings to the
transaxle rear cover.
Tighten
Tighten the screw plugs to 7.4 NSm (65 lb–in).
3. Install the 2 seal rings to the transaxle rear cover.
4. Using the vernier calipers, measure the free length
of the O/D brake piston return spring together with
the spring seat.
S Standard free length : 18.99 mm (0.7476 in.)

AISIN AUTOMATIC TRANSAXLE 5A2 – 143
DAEWOO V–121 BL4
If the preload of counter driven gear does not satisfy the
specification, select the adjuster shim from the table below
and remeasure the valve. Until the valve is within the spec-
ification, repeat the procedure.
Notice : When the preload is larger than the specification,
select a thinner adjuster shim. When the preload is smaller
than specification, select a thicker adjuster shim.
S Adjuster shim thickness: mm (in.)
Mark
ThicknessMarkThickness
11.70 (0.0669)G2.17 (0.0854)
21.75 (0.0689)H2.20 (0.0866)
31.80 (0.0709)K2.25 (0.0886)
41.85 (0.0728)L2.30 (0.0906)
51.90 (0.0748)M2.35 (0.0925)
61.93 (0.0760)N2.40 (0.0945)
71.96 (0.0772)P2.45 (0.0965)
A1.99 (0.0783)Q2.50 (0.0984)
B2.02 (0.0795)R2.55 (0.1004)
C2.05 (0.0807)S2.60 (0.1024)
D2.08 (0.0819)U2.65 (0.1043)
E2.11 (0.0831)W2.70(0.1063)
F2.14 (0.0843)––
30. Using the vernier calipers, measure the free length
of the 1st & reverse brake piston return spring to-
gether with spring seat.
S Standard free length: 18.053 mm (0.71075 in.)
31. Check to see if the sliding surface of the disc, plate
and flange of 1st & reverse brake are worn or burnt.
If necessary, replace them.
Notice : If the lining of the disc is peeling off or discolored,
or even if a part of the groove is defaced, replace all discs.
Notice : Before assembling new discs, soak them in ATF
for at least 15 minutes.

AISIN AUTOMATIC TRANSAXLE 5A2 – 145
DAEWOO V–121 BL4
36. Using 1st & reverse brake adapter DW240–070 and
brake spring compressor bolt/nut DW240–060–01,
install the snap ring.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
37. Using a dial indicator, measure the 1st & reverse
brake piston stroke while applying and releasing
392–785 kPa (57–114 psi) of compressed air.
Notice : If the piston stroke is non–standard, inspect the
discs, plates and flange. Piston stroke 0.6
1.3 mm (0.024

0.051 in.)
38. Using counter drive gear installation adapter
DW240–100, brake spring compressor bolt/nut
DW240–060–01 and brake spring compressor plate
DW240–060–02, install the counter drive gear.
Notice : Be careful not to apply excessive force to the
transaxle case.
39. Coat a new oil seal with ATF.
40. Install the oil seal to the transaxle case.
S Oil seal in depth:
A: 1 ± 0.25 mm (0.39 ± 0.0098 in.)

5A2 – 148IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
50. Install the parking lock pawl bracket with the 2
bolts.
Tighten
Tighten the bolts to 7.4 NSm (65 lb–in).
51. Using counter drive gear installation adapter
DW240–100 and brake spring compressor bolt/nut
DW240–060–01,install the planetary ring gear.
S Before installing the planetary ring gear, be sure
to replace the planetary ring flange of the plane-
tary ring gear with a new one.
52. Fix the counter drive gear with parking lock pawl.
53. Using planetary ring gear nut removal/installation
socket DW260–041, install a new nut.
Tighten
Tighten the nut to 9.8 NSm (87 lb–in).

AISIN AUTOMATIC TRANSAXLE 5A2 – 149
DAEWOO V–121 BL4
54. Using a small torque wrench, while turning to count-
er drive gear 100 turn per minute and measure the
preload.
Notice : When the preload is smaller than the specifica-
tion, tighten the nut more and adjust the preload. Preload:
0.05–0.35 NSm (0.43–3.12 lb–in)
Tighten
Tighten the nut to 29 NSm (22 lb–ft) or less.
55. Stake the nut.
56. Install the planetary gear to the transaxle case.
57. Coat the planetary carrier thrust washer with petro-
leum jelly and install it onto the planetary gear.
58. Install the No.2 one–way clutch to the transaxle
case.

5A2 – 150IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
59. Check that the planetary gear turns freely counter-
clockwise and locks clockwise.
60. Install the anti–rattle clip in the place shown in the
illustration (the space between the No.2 one–way
clutch outer race and transaxle case), push the
anti–rattle clip in until you hear the ”click”.
61. Using vernier calipers, measure the free length of
the 2nd brake piston return spring together with
spring seat.
S Standard free length: 15.85 mm (0.6240 in.).
62. Check to see if the sliding surface of the disc, plate
and flange of 2nd brake are worn or burnt. If neces-
sary, replace them.
Notice : If the lining of the disc is peeling off or discolored,
or even if a part of the groove is defaced, replace all discs.
Notice : Before assembling new discs, soak them in ATF
for at least 15 minutes.

5A2 – 152IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
68. Using brake spring compressor bolt / nut
DW240–060–01 and 2nd brake adapter
DW240–080, compress the 2nd brake piston return
spring.
69. Using a screwdriver, install the snap ring.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
70. Coat the thrust bearing race with petroleum jelly
and install it onto the front planetary sun gear.
S Race:
Inner diameter: 19.3 mm (0.760 in.)
Outer diameter : 29.0 mm (1.142 in.)
71. Install the front planetary sun gear to the transaxle
case.
72. Install the thrust washer and one–way clutch as-
sembly to the rear planetary sun gear.

AISIN AUTOMATIC TRANSAXLE 5A2 – 155
DAEWOO V–121 BL4
81. Check to see if the sliding surface of the disc, plate
and flange of 2nd coast & O/D brake are worn or
burnt. If necessary, replace them.
Notice : If the lining of the disc is peeling off or discolored,
or even if a part of the printed mark is defaced, replace all
discs.
Notice : Before assembly new discs, soak them in ATF for
at least 15 minutes.
82. Using a screwdriver, install the snap ring to the
transaxle case.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
83. Install the flange, 2 discs and 2 plates to the trans-
axle case.
S Install in order: P
D
P
D
F
(P = Plate, D = Disc, F = Flange)
84. Clean the connected part the transaxle case and
transaxle rear cover.
85. As shown in the illustration, place a straight edge
on the transaxle case and measure the distance
between the 2nd coast & O/D brake flange and
straight edge using vernier calipers. (Dimension A).

5A2 – 164IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
124. Install the No.1 breather plug.
125. Install the input shaft speed (ISS) sensor with
the bolt.
Tighten
Tighten the bolts to 5.4 NSm (48 lb–in).
126. Coat a new O–ring with ATF, install it to the
screw plug.
127. Install the screw plug to the transaxle case.
Tighten
Tighten the bolts to 7.4 NSm (65 lb–in).
128. Coat new 2 O–rings with ATF, install them to
the unions.
129. Install the 2 unions to the transaxle case.
Tighten
Tighten the unions to 25 NSm (18 lb–ft).
130. Install the TR switch onto the manual valve
lever shaft and temporarily install the 2 adjusting
bolts.
131. Install a new lock washer and nuts.
Tighten
Tighten the nuts to 12 NSm (106 lb–in).

AISIN AUTOMATIC TRANSAXLE 5A2 – 165
DAEWOO V–121 BL4
132. Temporarily install the control lever.
133. Turn the lever counterclockwise until it stops,
then turn it clockwise 2 notches.
134. Remove the control lever.
135. Align the groove with neutral basic line.
136. Tighten the 2 bolts.
Tighten
Tighten the bolts to 5.4 NSm (48 lb–in).
137. Using a screwdriver, stake the nut with the lock
washer.