automatic transaxle DAEWOO NUBIRA 2004 Service Repair Manual

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17. Install the transaxle housing and 16 bolts of the
transaxle housing temporarily.
18. Tighten 8 or 9 bolts out of 16 bolts of the transaxle
housing completely.
Tighten
Tighten the bolts to 29 NSm (22 lb–ft).
19. Using differential preload adapter DW240–130, turn
the differential gear assembly right and left 2 or 3
times to allow the bearing settle.
20. Using differential preload adapter DW240–130 and
small torque wrench, measure the preload of the
differential gear.
S Preload:
New bearing: 0.78–1.37 N.m (6.9–12.2 lb –in)
Used bearing : 0.39–0.69 N.m (3.5
6.1 lb–in)
If the preload is not within the specification, re-
move the differential from the transaxle case.
Re–select the transaxle case side adjusting
shim according to the following table.
S Adjusting shim thickness :mm (in.)
Mark
ThicknessMarkThickness
A1.80 (0.0709)N2.26 (0.0890)
B1.85 (0.0728)P2.29 (0.0902)
C1.90 (0.0748)Q2.32 (0.0913)
D1.95 (0.0768)R2.35 (0.0925)
E2.00 (0.0787)S2.40 (0.0945)
F2.05 (0.0807)T2.45 (0.0965)
G2.08 (0.0819)U2.50 (0.0984)
H2.11 (0.0831)V2.55 (0.1004)
J2.14 (0.0843)W2.60 (0.1024)
K2.17 (0.0854)X2.65 (0.1043)
L2.20 (0.0866)Y2.70 (0.01063)
M2.23 (0.0878)

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21. Using a plastic hammer, remove the 16 bolts and
transaxle housing.
22. Remove the differential gear from the transaxle
case.
23. Clean the contact surface of the differential case.
24. Heat the ring gear in water and boil for 10 minutes.
25. Carefully remove the ring gear from the water.
26. After the moisture on the ring gear has completely
evaporated, quickly install the ring gear to the differ-
ential case.
27. Install the 8 bolts.
Tighten
Tighten the bolts to 102 NSm (75 lb–ft).

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28. Using transaxle housing oil seal installer
DW260–031–01 and a hammer, drive in a new
transaxle housing oil seal .
S Oil seal in depth : 3.1 mm (0.122 in.)
29. Using transaxle case oil seal installer
DW260–031–02, drive in a new transaxle case oil
seal.
S Oil seal in depth : 4.3 mm (0.169 in.)

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GENERAL DESCRIPTION
AND SYSTEM OPERATION
TRANSAXLE DESCRIPTION
The new automatic transmission is an electronically con-
trolled 4–speed automatic transmission with Lock–up
mechanism.
The transmission is mainly composed of the torque con-
verter with lock up clutch, newly developed 4–speed plan-
etary gear unit, the hydraulic control system and the elec-
tric control system.
ELECTRONICAL COMPONENTS
Transmission Control Module (TCM)
The TCM primarily controls shift points and lockup en-
gagement. It is located on the driver side under the instru-
ment panel.
The transmission is controlled by an electronic shift sys-
tem. The Transmission Control Module (TCM) processes
input signals. From the information received, the TCM
controls the transmission hydraulic system.
The electronic shift system consists of the following :
S Transmission control module (TCM)
S Shift solenoids (SS1 and SS2)
S Pressure control solenoid (PCS)
S Lockup solenoid
S Input shaft speed (ISS) sensor
S Output shaft speed (OSS) sensor
S Transmission Fluid Temperature (TFT) sensor
S Transmission Range (TR) Switch
Transmission Range (TR) Switch
Transmission Range (TR) Switch transmits the informa-
tion which range includes shift lever of A/T to Starter and
TCM.
S It is possible for TR switch to start an engine in only
”P” and ”N”. (Prevention of reckless driving)
S TR switch makes backup lamp turn on when re-
versing.
S It is used for TR switch to shift control.
TR switch transmits the information by combination of
starter and reverse circuit to vehicle side directly without
TCM.
Shift Solenoid No 1,2 (SS1, SS2)
2 shift solenoids are installed directly in the valve body.
The solenoids operate of ON and OFF by the control sig-
nal from TCM. Combinations of 2 solenoids, SS1 and SS2
changes gear ranges.

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Timing Solenoid
Timing solenoid is installed directly in the valve body. The
solenoid operates of ON/OFF by the control signal from
TCM. The solenoid change timing valve of inside the valve
body, operate hydraulic control with apply and drain of for-
ward clutch.
Lock–Up Solenoid
Lock–up solenoid is installed in the valve body. It recieves
control signal from TCM.
Lock–up solenoid operates the lock–up valve inside the
valve body and controls the torque converter lockup func-
tion.
Pressure Control Solenoid (PCS)
The pressure control solenoid (PCS) is located inside the
valve body and regulates the transmission’s fluid pressure
system. It is internally grounded in the TCM and operates
when it is supplied with battery voltage from the TCM,
through the PCS and back to the TCM.
The battery voltage is controlled by a varying current from
the TCM.
The strength of the current is a function of the throttle posi-
tion.
Transmission Fluid Temperature (TFT)
Sensor
TFT sensor provides TCM with information on the trans-
mission fluid temperature.
The TCM uses information from the TFT sensor to calcu-
late the gear shift points and to engage the torque convert-
er lockup function.
Input Shaft Speed (ISS) Sensor
ISS sensor is located on the upper position of the transaxle
and detects A/T input speed from the rotation number of
the direct clutch drum.
They transmit to TCM as a signal.

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Output Shaft Speed (ISS) Sensor
OSS sensor is located on the upper position of the trans-
axle and detects the vehicle speed from the rotation num-
ber of the differential gear.
Shift Control
When the ATF is below specification (15°C), 4th up–shift
is prevented.

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HYDRAULIC CONTROL SYSTEM
Based on the hydraulic pressure created by the oil pump, TCM sends signals to solenoid and hydraulic control system
governs the hydraulic pressure acting on the torque converter, planetary gear, clutches and brakes in accordance with
the vehicle driving conditions.

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AUTOMATIC TRANSAXLE SYSTEM
Function of Components
ComponentFunction
C1Forward ClutchConnects input shaft and front sun gear.
C2Direct ClutchConnects input shaft and planetary carrier.
C3Reverse ClutchConnects input shaft and rear sun gear.
B1O/D & 2nd BrakePrevents rear planetary sun gear from turning either clockwise
or counterclockwise.
B22nd BrakePrevents outer race of F1 from turning either clockwise or coun-
terclockwise, thus preventing the rear sun gear turning conter-
clockwise.
B31st & Reverse BrakePrevents planetary carrier from turning either clockwise or
counterclockwise.
F1No.1 One–way ClutchWhen B2 is operating, this clutch prevents rear sun gear from
counterclockwise.
F2No.2 One–way ClutchPrevents planetary carrier from turning counterclockwise.
Planetary GearThese gears change the route through which driving froce is
transmitted, in accordance with the operation of each clutch
and brake, in order to increase or reduce the input and output
speed.

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Operations of Clutches and Brakes
Clutch & BrakeOperation
C1Forward ClutchConnects intermediate shaft and front sun gear.
C2Direct ClutchConnects input shaft and Planetary carrier.
C3Reverse ClutchConnects intermediate shaft and rear sun gear.
B1O/D & 2nd BrakeLock rear sun gear
B22nd BrakeLock rear sun gear
B31st & Reverse BrakeLock Planetary carrier
F11way Clutch No.1Lock counterclockwise rotation of rear sun gear, when B2 op-
erations
F21way Clutch No.2Lock counterclockwise rotation of planetary carrier

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PositionSolenoidClutchBrakeOne–way
Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
PONONOFFOFFOFFOFFOFFOFFOFFOF
–FOF
–F
RV<9
Km/
hONONOFFOFFOFFONOFFOFFONOF
–FOF
–F
V
9K
m/hONONONOFFOFFOFFOFFOFFOFFOF
–FOF
–F
NONONOFFOFFOFFOFFOFFOFFOFFOF
–FOF
–F
D1stONONOFFONOFFOFFOFFOFFOFFOF
–FON
2ndONOFFOFFONOFFOFFOFFONOFFONOF
–F
3rdOFFOFFOFFONONOFFOFFONOFFOF
–FOF
–F
(3
4)OFFONON
OFFON
OFFONOFFOFF
ONONOFFOF
–FOF
–F
4thOFFONOFFOFFONOFFONONOFFOF
–FOF
–F
21stONONOFFONOFFOFFOFFOFFOFFOF
–FON
2ndONOFFOFFONOFFOFFONONOFFONOF
–F
3rdOFFOFFOFFONONOFFOFFONOFFOF
–FOF
–F
11stONONOFFONOFFOFFOFFOFFONOF
–FON
2ndONOFFOFFONOFFOFFONONOFFONOF
–F