5 Transaxle – Daewoo Matiz Service Manual

SECTION 5B

FIVE-SPEED MANUAL TRANSAXLE

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted.

TABLE OF CONTENTS

Description and Operation . . . . . . . . . . . . . . . . . . 5B-2

Five-Speed Manual Transaxle . . . . . . . . . . . . . . . 5B-2

Reverse Gear Misshift Preventing

Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2

Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2

Component Locators . . . . . . . . . . . . . . . . . . . . . . . 5B-3

Gear Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . 5B-3

Input Shaft and Counter Shaft Gear . . . . . . . . . . 5B-4

Gear Shift Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6

Differential and Case . . . . . . . . . . . . . . . . . . . . . . . 5B-7

Diagnostic Information and Procedure . . . . . . . 5B-8

General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5B-8

Checking Fluid Level . . . . . . . . . . . . . . . . . . . . . . . 5B-9

Changing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-9

Checking Transaxle Noise . . . . . . . . . . . . . . . . . . 5B-9

Checking Bearing Noise . . . . . . . . . . . . . . . . . . . . 5B-9

Repair Instruction . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10

On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10

Manual Transaxle Assembly . . . . . . . . . . . . . . . 5B-10

Gear Shift Control Case Assembly . . . . . . . . . . 5B-17

Speedometer Driven Gear and Cable . . . . . . . 5B-19

Gear Shift Control Cable . . . . . . . . . . . . . . . . . . 5B-21

Gear Shift Control Lever . . . . . . . . . . . . . . . . . . . 5B-23

Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-24

Gear Unit

Input Shaft

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-36

Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-41

Gear Shift Fork . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-46

Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-48

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Specifications . . . . . . . . . . . . . . . . . . . .

5B-52

5B-52

Fastener Tightening Specifications . . . . . . . . . . 5B-53

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-54

Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 5B-54

DAEWOO M-150 BL2

5B – 2 FIVE-SPEED MANUAL TRANSAXLE

DESCRIPTION AND OPERATION

FIVE-SPEED MANUAL TRANSAXLE

This five-speed transaxle assembly adopts the synchronized mesh type of 5 forward speed. The reverse speed gear is driven by sliding idle gear without synchronizer.

REVERSE GEAR MISSHIFT

PREVENTING MECHANISM

It prevents the gear from directly being shifted from 5th to reverse when shifting to reverse from 5th. Shift to the reverse in neutral position to prevent the shift cam from being interfered to the shift guide bolt.

D103B002

When shifting to reverse from neutral position between

5th and reverse, shift cam rotates to left and shifting is possible.

D103B001

In case of shifting to 5th gear, shift and select shaft rotates to right that shift cam aparts from guide bolt and moves upwards by returning spring. Therefore, shifting to reverse in this condition is impossible because of interference of guide bolt.

D103B003

DIFFERENTIAL

Differential is integrated with transmission case and installed on chassis together with engine. It changes the direction of power and increase torque by reducing speed.

Reduction gear is installed parallel to counter shaft and is helical gear type. Differential gear is bevel gear type and is integrated with reduction gear.

DAEWOO M-150 BL2

FIVE-SPEED MANUAL TRANSAXLE 5B – 3

COMPONENT LOCATORS

GEAR SHIFT CONTROL

1 Gear Shift Control Lever Knob

2 Gear Shift Cable Bracket

3 Select Cable

4 Shift Cable

DAEWOO M-150 BL2

5 Select Arm

6 Gear Shift Control Lever

7 Gear Shift Control Lever Guide

D13B4011


INPUT SHAFT AND COUNTER SHAFT GEAR

D13B4031

DAEWOO M-150 BL2

1 Input Shaft Circlip

2 5th Gear Synchronizer Plate

3 5th Gear Synchronizer Sleeve

4 5th Gear Synchronizer Spring

5 5th Gear Synchronizer Key

6 5th Gear Synchronizer Hub

7 5th Gear Synchronizer Ring

7-1 Wave Spring

8 Input Shaft 5th Gear

9 Input Shaft 5th Gear Bearing

10 Input Shaft 5th Gear Spacer

11 Input Shaft Bearing(Left)

12 Input Shaft 4th Gear

13 4th Gear Synchronizer Ring

13-1 Wave Spring

14 Input Shaft 4th Gear Bearing

15 3rd-4th Gear Synchronizer Sleeve

16 3rd-4th Gear Synchronizer Spring

17 3rd-4th Gear Synchronizer Key

18 3rd-4th Gear Synchronizer Hub

19 3rd Gear Synchronizer Ring

20 Input Shaft 3rd Gear

21 Input Shaft 3rd Gear Bearing

22 Input Shaft

23 Input Shaft Bearing(Right)


24 Input Shaft Oil Seal

25 Reverse Gear Shaft Bolt

26 Reverse Gear Shaft

27 Reverse Idle Gear

28 Counter Shaft Nut

29 Counter Shaft 5th Gear

30 Counter Shaft Bearing Shim

31 Counter Shaft Bearing(Left)

32 Counter Shaft 4th Gear

33 Counter Shaft 3rd-4th Gear Spacer

34 Counter Shaft 3rd Gear

35 Counter Shaft 2nd Gear

36 2nd Gear Synchronizer Ring

37 Counter Shaft 2nd Gear Bearing

38 1st-2nd Gear Synchronizer Circlip

39 1st-2nd Gear Synchronizer Sleeve

40 1st-2nd Gear Synchronizer Spring

41 1st-2nd Gear Synchronizer Key

42 1st-2nd Gear Synchronizer Hub

43 1st Gear Synchronizer Ring

44 Counter Shaft 1st Gear

45 Counter Shaft 1st Gear Bearing

46 Counter Shaft

47 Counter Shaft Bearing(Right)

DAEWOO M-150 BL2


GEAR SHIFT FORK

1 Shift and Select Shaft

2 Shift Interlock Bolt

3 Shift Lever

4 Select Lever

5 Shift and Select Shaft Boot

6 Gearshift Control Case

7 Shift Guide Bolt

8 Gearshift Control Case Guide Plate

9 Gearshift Control Case Gasket

10 Low Speed Shift Fork

11 Low Speed Shift Shaft

12 Low Speed Shift Shaft Spring/Ball

13 Low Speed Shift York

14 High Speed Shift York

15 High Speed Shaft Spring/Ball

16 High Speed Shift Shaft

17 High Speed Shift Fork

18 Reverse Shift Arm

19 5th/Reverse Shift Ball

20 5th/Reverse Shift Shaft Spring/Ball

21 Reverse Shift Shaft Guide Spring/Ball

22 5th/Reverse Shift Shaft

23 5th/Reverse Shift York

24 5th/Shift Fork Guide Ball

25 5th/Shift Fork

26 Reverse Shift Lever

D13B4021

DAEWOO M-150 BL2


DIFFERENTIAL AND CASE

1 Speedometer Driven Gear

2 Oil Level Plug

3 Case Cap O–ring(Left)

4 Case Cap(Left)

5 Back Up Light Switch

6 Transaxle Case(Right)

7 Oil Plate

8 Transaxle Case(Left)

9 Oil Drain Plug

10 Oil Gutter

11 Side Cover Plate

12 Side Cover

13 Differential Ring Gear

DAEWOO M-150 BL2

14 Differential Oil Seal(Left)

15 Differential Bearing(Left)

16 Differential Case

17 Speedometer Drive Gear

18 Differential Bearing(Right)

19 Differential Oil Seal(Right)

20 Differential Pinion Gear Shaft Pin

21 Differential Side Gear Adjust Shim

22 Differential Side Gear

23 Differential Pinion Gear Shaft

24 Differential Pinion Gear

25 Differential Pinion Gear Washer

D13B4041


DIAGNOSTIC INFORMATION AND PROCEDURE

GENERAL DIAGNOSIS

Condition

Gear Slipping Out of Mesh

Gear Catching

Hard Shifting

Noise in the Neutral Gear

Noise in the All Gears

Noise in the Peculiar Gear

Leak of Lubricant

Probable Cause Correction

D

Worn shift fork.

D

Replace shift fork.

D

Worn synchronizer sleeve or gear.

D

Replace sleeve or gear.

D

Worn bearings on input shaft or counter shaft.

D

Replace bearing.

D

Weakened or damaged location spring.

D

Loose or damaged synchronizer spring.

D

Excessive back-lash of gear.

D

Bent or distorted shift shaft or shift fork.

D

Weakened or damaged synchronizer spring.

D

D

Replace spring.

Replace synchronizer spring.

Adjust back-lash of gear.

Replace shift shaft or shift fork.

Replace spring.

D

Worn synchronizer ring.

D

Replace synchronizer ring.

D

Worn synchronizer sleeve or gear.

D

Replace sleeve or gear.

D

Bent or distorted shift shaft.

D

Excessive free travel of all gears in axial direction.

D

Replace shift shaft.

D

Replace gear.

D


D

Replace bearing.

D

D

D

D

D

Poor adjustment of clutch cable.

Distorted or broken clutch disc.

Damaged pressure plate.

Insufficient lubricant.

Worn input shaft gear.

D

Worn bearings on the input shaft gears.

D

Worn clutch release bearing.

D

Insufficient lubricant.

D


D

Adjust clutch cable.

D

Replace clutch disc.

D

Replace pressure plate.

D

Supply lubricant.

D

Replace gear.

D

Replace bearing.

D

D

D

Replace clutch release bearing.

Supply lubricant.

Replace bearing.

D

Worn input shaft or counter shaft gear.

D

Worn or damaged synchronizer ring.

D

Worn or damaged synchronizer sleeve.

D

D

D

D

Replace gear.

D

D


Replace synchronizer sleeve.

D

Replace gear or bearing.

D


D

Worn differential gear or bearing.

D

Worn or damaged synchronizer ring in the peculiar gear.

D

Worn or damaged gear in the peculiar gear.

D

Worn or damaged bearing in the peculiar gear.

D

Damaged gasket, oil seal or

O-ring.

D

D

D

Replace gear.

Replace bearing.

Replace gasket, oil seal or O-ing.

DAEWOO M-150 BL2

CHECKING FLUID LEVEL

Check for a leak in the area of transaxle case and sealing and then check fluid level and condition after removing oil level plug.

1. Operate the engine until it comes to normal operating temperature(Coolant temperature : 80~90

°

C (176~

194

°

F)).

2. Stall the engine and raise the vehicle.

3. Remove the oil level plug and check the fluid level.

4. The fluid should slightly flow out from the oil level plug hole.

5. If the level is low, add the recommended fluid through the oil level plug hole until the fluid begins to run out.

6. If the fluid is contaminated or discolored, replace it with the recommended fluid.

7. Reinstall the oil level plug and tighten it securely.

D103B301

CHANGING FLUID

1. Operate the engine until it comes to normal operating temperature(Coolant temperature : 80~90

°

C (176~

194

°

F)).

2. Stall the engine and raise the vehicle.

3. Drain the fluid after removing the drain plug.

4. Reinstall the drain plug and tighten it securely after coating sealant.

5. Remove the oil level plug and replenish the fluid until it begins to run out.

a. Oil drain plug.

b. Oil level plug.

6. Reinstall the oil level plug and tighten it securely.


Fluid Specification

Fluid Capacity

Service interval

75W-85(GL-4)

2.1L(2.21qt)

Refer to Owner’s Manual

CHECKING TRANSAXLE NOISE

Many noises that appear to come from the transaxle may actually originate with other sources such as tires, road surfaces, wheel bearings, or engine and exhaust system.

Identify the cause of any noise before attempting to repair the clutch, the transaxle, or their related linkages.

To verify suspected transaxle noises,

1. Select a smooth, level asphalt road to reduce tyre and resonant body noise.

2. Drive the vehicle far enough to warm up all the lubricants thoroughly.

3. Record the speed and the gear range of the transaxle when the noise occurs.

4. Check for noises with the vehicle stopped, but with the engine running.

5. Determine if the noise occurs while the vehicle operates in.

D

Drive – Under a light acceleration or a heavy pull.

D

Float – Maintaining a constant speed with a light throttle on a level road.

D

Coast – With the transaxle in gear and the throttle partly or fully closed.

D

All of the above.

CHECKING BEARING NOISE

Differential Side Bearing Noise

Differential side bearing noise and wheel bearing noise can be confused easily. Since side bearings are preloaded, a differential side bearing noise should not diminish much when the differential/transaxle is run with the wheels off the ground.

Wheel Bearing Noise

Wheel bearings produce a rough growl or grating sound that will continue when the vehicle is coasting and the transaxle is in NEUTRAL. Since wheel bearings are not pre-loaded, a wheel bearing noise should diminish considerably when the wheels are off the ground.

DAEWOO M-150 BL2


REPAIR INSTRUCTION

ON–VEHICLE SERVICE

D103B501

MANUAL TRANSAXLE ASSEMBLY

Tools Required

DW110–021 Engine Support Fixture

DW220–031 Transaxle Remove/Install Support

Removal Procedure

1. Remove the air cleaner assembly. Refer to Section

1B, SOHC Engine Mechanical.

2. Remove the battery and battery tray. Refer to Section

1E, Engine Electrical.

3. Disconnect the select and the shift cable.

D

Remove the cable pins (1).

D

Remove the washers (2).

D

Disconnect the select and the shift cable (3).

D

Remove the cable E–rings (4).

D

Disconnect the cables from the cable bracket.

D103B502

4. Remove the engine wiring harness bending strap.

5. Disconnect the ground wire and the backup lamp switch connector.

D

Remove the ground wire bolt (1).

D

Disconnect the ground wire (2).

D

Disconnect the backup lamp switch connector (3).

DAEWOO M-150 BL2

DAEWOO M-150 BL2


6.

Disconnect the radiator lower hose.

D

Remove the bolts (1).

D

Disconnect the radiator lower hose (2).

7.

Remove crankshaft position (CKP) sensor.

D

Remove the bolt (3).

D

Disconnect the CKP sensor connector

D

Remove the CKP sensor.

D13B5031

8.

Disconnect the speedometer cable.

D

Loosen the nut (1).

D

Disconnect the cable (2).

9.

Remove the vehicle speed sensor (VSS) if equipped.

D

Disconnect VSS connector.

D

Remove the VSS.

D103B507

10. Remove the starter motor.

D

Remove upper two bolts that securing starter motor to transaxle.

D102E502

11. Fix the engine assembly.

D

Remove the cowl panel weatherstrip.

D

Position the engine support fixture DW110–021 on the cowl panel and the front upper panel.

D

Tighten the engine fixture joint with a bolt after removing exhaust manifold bolt (No.4).

D13B5041


12. Remove the transaxle upper bolts.

a. Exhaust manifold side bolt.

b. Thermostat housing side bolt.

D103B510

13. Remove the transaxle under cover.

D


D

Remove the transaxle under cover (2).

14. Remove the front tires and wheels.

D103B505

15. Drain the transaxle fluid.

D

Remove the drain plug and drain the fluid.

16. Disconnect the clutch cable.

D

Remove the cable adjust nut (1).

D

Disconnect the cable from the wire clip (2).

D

Disconnect the cable from the transaxle mount hole (3).

D103B506

17. Remove the front under longitudinal frames and stabilizer. Refer to Section 2C, Front Suspension.

18. Remove the drive axle (only transaxle side). Refer to Section 3B, Manual Transaxle Drive Axle.

19. Remove the clutch housing lower plate.

D


D

Remove the lower plate (2).

D103B509

DAEWOO M-150 BL2

DAEWOO M-150 BL2


20. Remove the front exhaust pipe.

D

Remove the front exhaust pipe nuts (exhaust manifold side) (1).

D

Remove the gasket and separate exhaust manifold pipe (2).

D

Make free the front exhaust pipe.

D12B5731

21. Support the transaxle with the transaxle remove/ install support DW220–030N.

D

Position the support on the jack (a).

D

Support the transaxle case and mount using a jack and the transaxle remove/install support.

D13B5111

22. Remove the transaxle lower bolt and nut.

a. Lower bolt.

b. Lower nut.

D103B512

23. Remove the transaxle mount bolts.

D13B5131


24. Position the manual transaxle assembly in tilting.

D

To remove the manual transaxle side cover without the interference with the front under longitudinal panel (Left), tilt the engine/manual transaxle by loosening the engine support fixture DW110– 021 joint with the wrench.

D13B5141

25. Remove the manual transaxle assembly.

D

Lower the transaxle assembly slowly by adjusting jack.

a. Jack.

b. Transaxle assembly.

D

Tilt the transaxle assembly by adjusting jack.

D

Remove the transaxle assembly by pulling and lowering it slowly.

D13B5151

26. Support the engine to normal position using the engine support fixture DW110–021.

Notice: The abnormal position of the engine may damage to the related parts or interfere with them. You have to support the engine to normal position when removing the transaxle.

Important: If it is impossible to use the special tool, support the engine to normal position with the auto jack.

D103B516

Installation Procedure

1. Install in the reverse order of removal.

2. Install the transaxle mounting bolts.

Tighten

Tighten the transaxle mounting bolts (body side) to

45–55 N

S m (33–41 lb-ft).

D13B5171

DAEWOO M-150 BL2

DAEWOO M-150 BL2


3. Install the transaxle lower bolt, nut.

Tighten

Tighten the bolt and nut to 55–65 N

S m (41–48 lb-ft).

a. Lower bolt.

b. Lower nut.

D13B518A

4. Tighten the front exhaust pipe nuts.

Tighten

D

Tighten the front exhaust pipe nuts (exhaust manifold side) to 25–35 N

S m (18–25 lb-ft).

D13B5472

5. Install the transaxle upper bolts.

Tighten

Tighten the bolts to 55–65 N

S m (41–48 lb-ft).

a. Exhaust manifold side bolt.

b. Thermostat housing side bolt.

D13B519A

6. Install the starter motor.

Tighten

Tighten the starter motor bolts to 18–28 N

S m (13–21 lb-ft).

7. Connect all electric connectors.

D13B548A


8. Install the radiator lower hose and crank position

(CKP) sensor.

Tighten

Tighten the radiator lower hose bolt to 8–15 N

S m

(70–132 lb-in).

Tighten the CKP sensor bolt to 5–8 N

S m (44–70 lbin).

D13B5032

D13B520A

9. Refill the transaxle fluid.

D

Tighten the drain plug to 25–30 N

S m (18–22 lb-ft)

(a).

D

Remove the oil level plug (1).

D

Refill recommended fluid to the proper level.

ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ Classification 75W – 85 (GL–4)

ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ

Capacity 2.1L (2.21 qt)

ÁÁÁÁÁÁÁÁÁ

D

Tighten the oil level plug to 36–54 N

S m (26–40 lb-ft)

(b).

10. Adjust the clutch cable. Refer to Section 5C, Clutch.

D

Adjust the clutch cable by the clutch cable adjust nut.

11. Install the transaxle under cover.

Tighten

Tighten the transaxle under cover bolts to 35–55

N

S m (25–41 lb-ft).

D13B521A

D103B501

GEAR SHIFT CONTROL CASE

ASSEMBLY


1. Remove the air hose (air cleaner to throttle body).

Refer to Section 1B, SOHC Engine Mechanical.

2. Remove the battery.

3. Disconnect the select and the shift control cable.

D


D


D

Disconnect the select and the shift control cable

(3).

D


D


DAEWOO M-150 BL2

DAEWOO M-150 BL2


4. Remove the select lever.

D


D

Remove the select lever (2).

D103B522

5. Remove the shift interlock bolt.

Important: Certainly remove the shift interlock bolt.

Otherwise, the gear shift control case can not be removed.

D103B523

6. Remove the gear shift control case assembly.

D


Important: Make sure the gear shift lever is in NEU-

TRAL.

D

Remove the gear shift control case assembly (2).

D

Remove the gasket (3).

D103B524

7. Remove the shift lever.

D

Position the gear shift control case assembly to the vice with a protector.

D

Remove the lever pin with a pin punch and a hammer (1).

D

Remove the shift lever (2).

D

Remove the boot (3).

D103B525


8. Remove the select/shift shaft.

D

Remove the shift guide bolt (1).

D

Remove the select/shift shaft (2).

D103B526

9. Remove the gear shift control case plate.

D


D

Remove the Plate from the case (2).

D103B527

Inspection Procedure

1. Inspect for worn or damaged the fifth/reverse shift cam (1).

2. Inspect for worn or damaged shift interlock plate (2).

3. Inspect for worn or damaged select/shift lever (3).

4. Inspect for bent or damaged select/shift shaft (4).

D103B528



2. Install the shift guide bolt.

Tighten

Tighten the shift guide bolt to 18–28 N

S m (13–21 lb-ft).

D13B529A

DAEWOO M-150 BL2

DAEWOO M-150 BL2

D13B530A


3. Install the gear shift control case and the select lever.

Tighten

D

Tighten the gear shift control case bolts to 18–28

N

S m (13–21 lb-ft).

a. Gear shift control case bolt.

D

Tighten the select lever bolts to 18–28 N

S m (13–21 lb-ft).

b. Select lever bolt.

Important: Make sure a correct bolt. There is length difference between select lever bolts.

4. Install the shift interlock bolt.

Tighten

Tighten the shift interlock bolt to 18–28 N

S m (13–21 lb-ft).

D13B531A

D103B532

SPEEDOMETER DRIVEN GEAR AND

CABLE

(Left–Hand Drive Shown, Right–Hand

Drive Similar)


1. Remove the speedometer driven gear assembly.

D

Loosen the nut. (1).

D


D


D

Remove the speedometer driven gear assembly

(4).

D

Disconnect the vehicle speed sensor connector (If equipped).

a. Vehicle speed sensor connector.

D

Disconnect the vehicle speed sensor.

b. Vehicle speed sensor.

Caution: Be careful to prevent personal injury while the exhaust pipe is hot.

D103B533


2. Remove the battery. Refer to Section 1E, Engine

Electrical.

3. Disconnect the instrument cluster side cable. Refer to

Section 9E, Instrumentation/Driver Information.

4. Remove the speedometer cable.

D

Remove the cable grommet (1).

D

Pull out the speedometer cable from the dash panel.

D103B534

D103B535

Inspection Procedure

1. Remove the O–ring from the speedometer driven gear housing.

2. Remove the driven gear pin and disconnect the driven gear.

D

Check for a damaged or torn O–ring.

D

Check for a worn or damaged tooth of driven gear.

a. O–ring.

b. Driven gear pin.

c. Driven gear.



Important: Install the speedometer driven gear assembly after connecting the speedometer cable with the speedometer driven gear assembly completely.

D103B536

2. Install the speedometer driven gear assembly to transaxle housing.

Tighten

Tighten the speedometer driven gear assembly bolt to 4–7 N

S m (35–62 lb-in).

D13B537A

DAEWOO M-150 BL2

DAEWOO M-150 BL2

D103B501


GEAR SHIFT CONTROL CABLE


1. Remove the air hose (air cleaner to throttle body).

Refer to Section 1B, SOHC Engine Mechanical.

2. Remove the battery.

3. Disconnect the transaxle side select and shift control cable.

D


D


D

Disconnect the select and shift control cable (3).

D


D


4. Remove the floor console. Refer to Section 9G, Inte-

rior Trim.

D

Put aside the floor carpet in order to get the gear shift cable shown.

D19E573A

5. Disconnect the gear shift lever side select and shift control cable.

D

Remove the select control cable clip (1).

D

Ply off the eye ring (2).

D

Remove the select control cable E–ring (3).

D

Disconnect the select control cable (4).

D

Remove the shift control cable pin (5).

D

Remove the shift control cable E–ring (6).

D

Ply off the shift control cable (7).

D13B5381

6. Remove the select and shift control cable.

D

Remove the nuts (1).

D

Pull the cables out in the passenger room.

D13B539A




2. Push the cables toward the engine compartment through dash panel’s hole slightly.

3. Position the cables on the select and the shift lever.

D103B540

D13B5411

4. Connect the transaxle side select and shift control cable.

5. Connect the gear shift lever side shift control cable.

6. Connect the gear shift lever side select control cable.

D

Insert the select control cable eye ring to the select arm pin (1).

D

Install the selector lever control cable clip (2).

D

Install the select control cable to gear shift lever bracket with E–ring (3).

D

Insert a driver to the select arm adjustment hole to prevent the movement of gear shift lever in NEU-

TRAL (4).

7. Tighten the adjust nuts.

Tighten

Tighten the select cable adjust nut to 8–12 N

S m

(71–106 lb-in).

D103B543

GEAR SHIFT CONTROL LEVER


1. Remove the floor console. Refer to Section 9G, Inte-

rior Trim.

2. Disconnect the select and shift control cable. Refer to

“Gear Shift control cable” in this section.

3. Remove the gear shift control lever assembly.

D


D

Remove the gear shift control lever assembly (2).

D

Remove the gear shift lever sensor connector.

(If equipped with auto clutch).

DAEWOO M-150 BL2

DAEWOO M-150 BL2

D13B544A




2. Install the gear shift control lever assembly.

Tighten


S m (35–62 lb-in).

3. Adjust the select cables. Refer to “Gear Shift Control

Cable” in this section.


MAINTENANCE AND REPAIR

UNIT REPAIR

D13B701A

GEAR UNIT

Tools Required

09913–76010 Bushing, Seal Installer

DW09940–53111 Gear, Bearing Installer

DW09943–78210 Bushing, Seal Installer

DW220–010A Transaxle Fixture

KM519 Oil Seal Installer

Disassembly Procedure

1. Remove the manual transaxle. Refer to “Manual

Transaxle Assembly” in this section.

2. Position the manual transaxle to a transaxle stand using the transaxle fixture DW220–010.

3. Remove the related clutch parts. Refer to Section 5C,

Clutch.

4. Remove the manual transaxle mounting bracket.

D


D

Remove the nut (2).

D

Remove the mounting bracket (3).

D13B7021

5. Disconnect the backup light switch and speedometer driven gear assembly.

D

Remove the nut (1).

D

Disconnect the backup light switch (2).

D


D

Remove the speedometer driven gear assembly

(4).

D103B703

DAEWOO M-150 BL2

DAEWOO M-150 BL2


6. Remove the select lever.

D


D

Remove the select lever (2).

D103B704

7. Remove the gear shift control case assembly.

D


D

Remove the shift interlock bolt (2).

Important: Certainly remove the shift interlock bolt.

Otherwise, gear shift control case can not be removed.

D

Remove the gear shift control case assembly (3).

D

Remove the gasket (4).

D103B705

8. Remove the side cover.

D


D

Remove the side cover using a rubber hammer (2).

D

Remove the sealant on the side cover and the transaxle case.

D103B706

9. Remove the fifth–gear shift fork guide ball, the snap ring and the input shaft fifth–gear snap ring.

D

Remove the fifth–gear shift fork plug (1).

D

Remove the guide ball using a magnet.

D

Remove the fifth–gear shift fork snap ring (2).

D

Remove the fifth–gear snap ring (3).

D

Remove the fifth–gear synchronizer plate.

D103B707


10. Remove the fifth–gear shift fork pin.

D

Shift the shift fork to the fifth–gear.

D

Remove the fork pin using a pin punch and a hammer (1).

D103B708

11. Remove the input shaft fifth–gear fork and synchronizer hub assembly.

D

Pull and remove the fork and the hub assembly together (1).

D

Remove the sleeve, key and spring from the synchronizer hub assembly.

D103B709

12. Remove the input shaft fifth–gear, the synchronizer ring and the fifth–gear bearing.

D

Pull and remove the fifth–gear, wave spring and synchronizer ring together (1).

D

Remove the fifth–gear bearing.

D103B710

13. Remove the countershaft fifth–gear.

D

Shift the shift yoke using a driver to engage the first–gear and the third–gear or the second–gear and the fourth–gear (1).

D

Remove the caulking and the nut. (2, 3)

D103B711

DAEWOO M-150 BL2

DAEWOO M-150 BL2


D

Remove the counter shaft fifth–gear (4).

D103B712

14. Remove the side cover plate and the counter shaft bearing shim.

D

Remove the screws (1).

D

Remove the side cover plate (2).

D

Remove the counter shaft bearing shim.

D103B713

D103B714

15. Remove the shift shaft spring and ball.

D

Remove the bolt and remove the fifth–reverse gear shift shaft spring and ball (1).

D

Remove the bolt and remove the third–fourth gear shift shaft spring and ball (2).

D

Remove the bolt and remove the first–second gear shift shaft spring and ball (3).

Important: There is difference between the fifth–reverse gear shift shaft spring and the others. Mark it to distinguish easily when installing.

16. Remove the reverse idle gear shaft bolt.

Important: The case (Left) can not be removed without removing the reverse idle gear shaft bolt.

D103B715


17. Remove the transaxle case (Left).

D

Remove the bolts from the left side case (1).

D

Remove the bolts, stud bolts if equipped with auto clutch.

D

Remove the bolts from the right side of case (2).

D

Remove the left side case by hitting with a rubber hammer lightly.

D

Remove the sealant on the case.

D103B716

18. Remove the reverse gear shift lever.

D


D

Remove the reverse gear shift lever (2).

D103B717

19. Remove the reverse idle gear shaft assembly.

D

Push the reverse idle gear toward inner case.

D

Pulling shaft and remove the reverse idle gear and shaft (1).

D

Remove the reverse idle gear from the shaft.

D103B718

20. Remove the fifth–reverse gear shift shaft.

a. Fifth–reverse gear shift shaft.

D103B719

DAEWOO M-150 BL2

DAEWOO M-150 BL2


21. Remove the gear unit.

D

Remove the gear unit and the shift shaft assembly together (1).

Notice: Be careful not to damage teeth of the counter shaft pinion and the differential ring gear.

D

Remove the high and the low speed shift shaft assembly from the gear unit.

D103B720

22. Remove the differential assembly.

D

Insert a wooden stick into the lower side of differential (1).

D

Remove the differential assembly by moving it right and left (2).

D103B721

23. Remove the related parts of the transaxle case (Left

Side).

D


D

Remove the oil gutter (2).

D


D

Remove the oil plate (4).

D

Remove the differential left side oil seal using a hammer and a copper chisel (5).

D103B722

D


D

Remove the case cap (Left Side) (7).

D

Remove the case cap O–ring (Left Side) (8).

D

Remove the oil level plug (including steel gasket)

(9).

D

Remove the counter shaft bearing outer race using a hammer and the gear, bearing installer DW

09940–53111.

D103B723


24. Remove the related parts of the transaxle case

(Right Side).

D

Remove the input shaft oil seal using a screwdriver (1).

D

Remove the differential left side oil seal using a hammer and a copper chisel (2).

D103B724

Synchronizer Sleeve and Shift Fork

Inspection

1. Measure the clearance between synchronizer sleeve and shift fork and if the clearance exceeds the limit, replace the shift fork.

Unit : mm (in.)

ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ

Standard Limit

ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ

Sleeve and Shift

ÁÁÁÁÁÁÁ

Fork

0.2

∼

0.6

(0.008

∼

0.024)

1.0

(0.039)

ÁÁÁÁÁÁÁ

D103B725

D103B726

Assembly Procedure

1. Install the related parts of the transaxle case (Right

Side).

D

Install the input shaft oil seal using the bushing seal installer DW09943–78210.

D

Install the differential right side oil seal using the bushing, seal installer 09913–76010.

Important: Use only a new oil seal.

Important: Coat the transaxle inner parts with gear fluid when installing.

2. Install the related parts of the transaxle case (Left

Side).

D

Install the oil plate with the bolts.

D

Install the oil gutter with the bolt.

D

Install the oil level plug (including steel gasket).

a. Oil level plug.

Tighten

Tighten the oil level plug to 36–54 N

S m (26–40 lb-ft).

D

Install the left side case cap with the bolts (including O–ring) (1).

D13B727A

DAEWOO M-150 BL2

DAEWOO M-150 BL2


Tighten

Tighten the bolt to 8–12 N

S m (71–106 lb-in).

b. Case cap retaining bolt.

D

Install the differential left side oil seal using the oil, seal installer KM519.

D13B727A

3. Install the differential assembly to the right side of transaxle case.

a. Differential assembly.

D

When the differential ring gear surface is lower than the right side of transaxle case surface, it is installed correctly.

D103B728

4. Install the low and the high speed shift shaft assembly to the gear unit.

5. Install the gear unit.

D

Push the gear unit by matching it with the input and the counter shaft hole (1).

Notice: Be careful not to damage teeth of the counter shaft pinion and the differential ring gear.

D103B729

D13B730A

6. Install the fifth–reverse gear shift shaft.

7. Install the reverse idle gear shaft assembly and the reverse gear shift lever.

D

Install the reverse idle gear shaft assembly (1).

Important: Match the marking of the reverse idle gear shaft bolt hole with the protrusion of the transaxle case

(Right Side).

D

Install the reverse gear shift lever (2).

Tighten


S m (13–21 lb-ft).


D13B731A

D13B732A

8. Install the shift shaft ball and spring.

D

Install the third–fourth gear shift shaft ball and spring.

Tighten


S m (7–12 lb-ft) (a).

D

Install the fifth–reverse gear shift shaft ball and spring.

Tighten


S m (7–12 lb-ft) (b).

Important: Install the fifth–reverse gear shift shaft spring marked when removing.

9. Install the transaxle left side case.

D

Coat the transaxle case with recommended sealant.

ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ

Transaxle Case Sealant THREE BOND 1215


D

Install the transaxle left side case to the transaxle right side case.

Tighten


S m (11–16 lb-ft) (a).

D

Tighten the bolts (8), stud bolts (3) if equipped with auto clutch.


S m (11–16 lb-ft) (b).

10. Install the first–second gear shift shaft ball and spring.

Tighten

Tighten the bolt to10–16 N

S m (7–12 lb-ft) (a).

11. Install the reverse idle gear shaft bolt.

Tighten


S m (13–21 lb-ft) (b).

D13B733A

12. Install the counter shaft bearing outer race.

D

Install the counter shaft bearing outer race using the gear, bearing installer DW09940–53111.

a. Bearing outer race.

Important: Check if the bearing and the outer race are correctly installed by rotating counter shaft.

D103B734

DAEWOO M-150 BL2

DAEWOO M-150 BL2

D13B735A


13. Install the counter shaft bearing shim.

D

Measure clearance between the transaxle case surface and the bearing outer race using a straight ruler and gauge.

D

Select shim in order that clearance is within standard.

Unit : mm (in.)

Measured value (A) Shim thickness

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ

0.33

−

0.37 (0.0130 – 0.0146)

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ

0.38

−

0.42 (0.0147 – 0.0165)


0.43

−

0.47 (0.0169 – 0.0185)


0.48

−

0.52 (0.0189 – 0.0205)


0.53

−

0.57 (0.0209 – 0.0224)


0.58

−

0.62 (0.0228 – 0.0244)


0.63

−

0.67 (0.0248 – 0.0264)


0.68

−

0.72 (0.0268 – 0.0283)


0.73

−

0.77 (0.0287 – 0.0303)


0.78

−

0.82 (0.0307 – 0.0323)


0.83

−

0.87 (0.0327 – 0.0343)


0.88

−

0.92 (0.0346 – 0.0362)


0.93

−

0.97 (0.0366 – 0.0382)


0.98 – 1.02 (0.0386 – 0.0402)


1.03 – 1.07 (0.0406 – 0.0421)


ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ a. Straight ruler b. Bearing outer race c. Case surface

D13B736A

14. Install the side cover plate and the counter shaft fifth gear.

D

Install the side cover plate (1).

Tighten

Tighten the screws to 6–7 N.m (53–62 lb–in).

Important: Use only new screws.

D

Install the counter shaft fifth gear (2).

Important: Position the machined boss side toward the side cover plate.


15. Install the counter shaft fifth gear nut.

D

Shift the shift yoke using a screwdriver to engage the first–gear and the third–gear or the second– gear and the fourth–gear (1).

Tighten

Tighten the fifth gear nut to 60–80 N

S m (44–59 lb-ft).

D

Caulk the nut using a chisel and a hammer (2).

D13B737A

16. Install the input shaft fifth gear bearing and the fifth gear / synchronizer ring.

D

Insert the bearing into the input shaft.

D

Install the fifth gear, wave spring and synchronizer ring matching synchronizer’s oil groove and input shaft punched mark (1).

D103B710

17. Install the fifth gear synchronizer hub assembly.

D

Install the synchronizer springs to hub (1).

D

Install the synchronizer key (2).

Important: In case of assembling synchronizer sleeve and hub, let A=B.

D

Position the longer boss side of hub toward inner side (3).

D

Position the chamfered spline of sleeve toward inner side and install the hub to the sleeve (4).

D103B738

18. Install the fifth gear fork to the synchronizer hub assembly.

19. Install the fifth gear fork and the synchronizer hub assembly to the input shaft.

Important: Position the longer boss side of hub toward inner side and match the synchronizer key and the hub groove with the input shaft punched mark.

D103B739

DAEWOO M-150 BL2

DAEWOO M-150 BL2


20. Install the fifth gear shift fork pin.

D

Push the shift fork toward the fifth gear.

D

Install the shift fork pin using a pin punch and a hammer(1).

Important: Use only new shift fork pin.

D103B740

21. Install the input shaft fifth gear snap ring, the fifth gear shift fork snap ring and guide ball.

D

Install the fifth gear synchronizer plate.

D

Install the fifth gear snap ring (1).

D

Install the fork snap ring (2).

Important: Use only new snap ring.

D

Tighten the fork plug after inserting the guide ball into the fork hole.

D103B741

22. Install the side cover(1).

D

Coat the side cover with recommended sealant.


Side Cover Sealant THREE BOND 1215


Tighten

Tighten the side cover bolts to 8–12 N

S m (71–106 lb-in).

D13B742A

D13B743A

23. Install the gear shift control case assembly.

D

Install the case gasket.

D

Install the gear shift control case.

Tighten

D


S m (13–21 lb-ft) (a).

D

Tighten the shift interlock bolt to 18–28 N

S m (13–

21 lb-ft) (b).

D

Install the select lever.

Tighten


S m (13–21 lb-ft) (c).


D13B744A

24. Install the backup light switch and the speedometer driven gear assembly.

D

Install the backup light switch (1).

Tighten

Tighten the nut to 15–18 N

S m (11–13 lb-ft) (a).

D

Install the speedometer driven gear assembly

(2).

Tighten


S m (35–62 lb-in) (b).

D

Install the hydraulic pump assembly (If equipped with auto clutch). Refer to Section 5D, Auto

Clutch.

25. Install the transaxle mount.

D

Install the mount (1).

Tighten

D


S m (41–48 lb-ft) (a).

D

Tighten the nut to 55–65 N

S m (41–48 lb-ft) (b).

D13B7452

26. Install the related clutch parts. Refer to Section 5C,

Clutch.

27. Remove the transaxle assembly from transaxle stand.

D

Remove the transaxle assembly using the transaxle fixture DW220–010A.

28. Install the transaxle assembly. Refer to “Manual

Transaxle Assembly” in this section.

D13B701A

D103B746

INPUT SHAFT

Tools Required

DW09921–57810 Gear, Bearing Remover




1. Remove the gear unit. Refer to “Gear Unit” in this section.

2. Remove the input shaft right side bearing.

D

Position the bearing to the gear, bearing remover

DW09921–57810.

D

Remove the bearing by pressing (1).

DAEWOO M-150 BL2

DAEWOO M-150 BL2


3. Remove the input shaft fifth gear spacer, the left side bearing and the fourth gear.

D

Position the fourth gear to the gear,bearing remover DW09921–57810.

D

Remove the following parts.

a. Fifth gear spacer.

b. Left side bearing.

c. Fourth gear

D103B747

4. Remove the fourth gear bearing.

5. Remove the fourth gear synchronizer ring and wave spring.

D103B748

6. Remove the third–fourth synchronizer circlip.

D103B749

7. Remove the third–fourth synchronizer hub assembly, the third gear 1 synchronizer ring.

D

Position the third gear to the gear, bearing remover

DW09921–57810.

D

Remove the following parts.

a. Third–fourth synchronizer hub assembly.

b. Third gear and synchronizer ring.

D103B750


8. Disassemble the third–fourth synchronizer hub assembly.

D

Remove the hub (1).

D

Remove the synchronizer sleeve and the key (2).

D

Remove the synchronizer springs (3).

D103B751

9. Remove the input shaft third gear bearing (1).

D103B752

Synchronizer Assembly Inspection

1. Inspecting wear of cone area.

D

After matching synchronizer ring to gear, measure as shown in figure. Replace if it is below limit.

Unit : mm (in.)


Standard Limit


Gear and Ring

1.0 (0.039) 0.5 (0.020)

ÁÁÁÁÁÁÁ

D103B753

2. Inspecting cone contact condition.

D

When synchronizer mechanism is abnormal in operation, connection between ring inner surface and gear cone area is considered to be partially defective in spite of correct clearance between gear and ring. Therefore, cone area and ring inner surface shall be inspected. In this case, ring inner surface shall be glossy. Black area is abnormal and if inspection is difficult, check after applying red lead.

Cone area can be worn in wave form.

D103B754

DAEWOO M-150 BL2

DAEWOO M-150 BL2

D103B755


3. Inspecting key slot width of synchronizer ring.

D

Measure key slot width of synchronizer ring. Replace if it exceeds limit.

Unit : mm (in.)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Key Slot Width Standard Limit


1st gear 8.2 (0.323) 8.6 (0.339)


2nd, 3rd, 4th gear

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

5th gear

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

9.6 (0.378)

9.4 (0.370)

10.0 (0.394)

9.8 (0.386)

ÁÁÁÁÁÁÁ

4. Inspecting wear of synchronizer ring.

D

Check for worn or damaged synchronizer ring teeth. Replace it if necessary.

D103B756

5. Inspecting synchronizer key and spring.

D

Check for worn synchronizer key (1).

D

Check for weak, damaged or broken spring (2).

D103B757


1. Install the third gear bearing, the third gear / synchronizer ring.

a. Third gear / synchronizer ring.

b. Third gear bearing.

Important: Coat the inner parts; gear, bearing, oil seal etc. with gear fluid.

D103B758


2. Assemble the third–fourth synchronizer hub assembly.

D

Install the synchronizer springs to the hub.

D

Install the synchronizer key to the hub.

Important: In case of assembling the synchronizer sleeve and the hub, let A=B.

D

Install the hub to the sleeve.

a. Sleeve.

b. Hub.

D103B759

3. Install the third–fourth synchronizer hub assembly.

D

Insert the hub assembly into the input shaft (1).

Important: Position the longer flange of hub toward the third gear and match the key and the ring groove.

D

Install the hub assembly using a hammer and the gear, bearing installer DW09940–53111.

D103B760

Notice: When installing gear, bearing and hub assembly, install them slowly using the gear, bearing installer

DW09940–53111 and a hammer. If overpressed, the gear teeth may be damaged.

D13B761A

4. Install the third–fourth synchronizer circlip.

5. Install the fourth synchronizer ring and wave spring.

Important: Match the ring groove to the key of hub.

D103B749

DAEWOO M-150 BL2

DAEWOO M-150 BL2


6. Install the input shaft fourth gear bearing and the fourth gear.

a. Fourth gear.

b. Fourth gear bearing.

D103B762

7. Install the input shaft left side bearing and the fifth gear spacer.

D

Install the following parts using the gear, bearing installer DW09925–98221 and a hammer.

a. Fifth gear spacer.

b. Input shaft left side bearing.

D103B763

8. Install the input shaft right side bearing.

D

Install the bearing to the input shaft using the gear, bearing installer DW09925–98221 and a hammer

(1).

9. Install the gear unit. Refer to “Gear Unit” in this section.

D103B764

D103B765

COUNTER SHAFT

Tools Required

09913–76010 Bushing, Seal Installer


DW09921–57810 Gear, Bearing Remover


DW09940–53111 Gear,Bearing Installer

DW220–020–01 Differential Bearing Puller

DW220–020–02 Differential Bearing Plate Adapter

DW220–020–03 Differential Bearing Plate Adapter

KM466–A Gear, Bearing Remover/Installer




2. Remove the counter shaft right side bearing.

3. Remove the counter shaft left side bearing and the fourth gear.

D

Position the fourth gear to the gear, bearing remover DW09921–57810.

D

Remove the following parts by pressing.

a. Counter shaft left side bearing.

b. Fourth gear.

D103B766

4. Remove the counter shaft third–fourth gear spacer.

5. Remove the counter shaft third gear and second gear.

D

Position the second gear to the gear, bearing remover DW09921–57810.

D

Remove the following parts by pressing a. Third gear.

b. Second gear.

D103B767

6. Remove the counter shaft second gear bearing.

7. Remove the second gear synchronizer ring.

8. Remove the first–second gear synchronizer circlip.

D103B768

DAEWOO M-150 BL2

DAEWOO M-150 BL2

D103B769


9.

Remove the counter shaft first–second gear synchronizer hub assembly, the first gear / the first gear synchronizer ring.

D

Position the first gear to the gear, bearing remover DW09921–57810.

D

Remove the following parts by pressing.

a. Synchronizer hub assembly.

b. First gear / First gear synchronizer ring.

D

Remove the first gear synchronizer ring from the first gear.

10. Disassemble the first–second gear synchronizer hub assembly.

D

Push the hub from the hub assembly (1).

D

Disassemble the synchronizer sleeve and key

(2).

D

Disassemble the synchronizer springs (3).

D103B770

11. Remove the counter shaft first gear bearing.

D103B771

Synchronizer Hub and Sleeve Inspection

D

Check the sleeve for improper operation after assembling the hub and the sleeve.

D

Check the wear of hub and sleeve.

D

Replace synchronizer hub or sleeve if necessary.

D103B772



1. Install the related counter shaft first gear.

D

Install the first gear bearing (1).

D

Install the first gear (2).

D

Install the first gear synchronizer ring (3)

Important: Coat the inner parts; gear, bearing and oil seal etc. with gear fluid.

Important: Be careful there is the difference of key groove width between the first synchronizer ring and the second synchronizer ring.

D103B773

Unit : mm (in.)

First synchronizer ring (A)


: 8.2 (0.323)

ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ

Key Groove Width

ÁÁÁÁÁÁÁÁÁ

Second synchronizer ring

ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ (B) : 9.6 (0.378)


D103B774A

2. Assemble the first–second synchronizer hub assembly.

D

Install the synchronizer springs to hub.

D

Install the synchronizer keys to hub.

Important: Let (A)=(B) when installing the keys.

D

Install the hub to the sleeve.

a. Sleeve.

b. Hub.

D103B775

3. Install the first–second synchronizer hub assembly.

D

Insert the hub assembly into the counter shaft using the gear, bearing installer DW09940–53111, the gear bearing remover/installer KM466–A and a hammer (1).

Important: Position the synchronizer key to the first gear synchronizer ring groove.

D103B776

DAEWOO M-150 BL2

DAEWOO M-150 BL2


4. Install the second synchronizer ring.

Important: Position the second synchronizer ring groove to the synchronizer hub key.

5. Install the first–second gear synchronizer circlip.

D103B768

6. Install the related counter shaft second gear.

D

Install the second gear bearing (1).

D

Install the second gear (2).

D103B777

7. Install the counter shaft third gear and the third–fourth gear spacer.

D

Insert the third gear and the third–fourth gear spacer into the counter shaft.

D

Install the following parts using the gear, bearing installer DW09913–80112 and a hammer.

a. Third–fourth gear spacer.

b. Third gear.

D103B778

8. Install the counter shaft fourth gear.

D

Install the fourth gear to the counter shaft using the gear, bearing installer DW09925–98221 and a hammer (1).

D103B779


9.

Install the counter shaft left side bearing.

D

Install the left side bearing to the counter shaft using the gear, bearing installer DW09925–98221 and a hammer (1).

D103B780

10. Install the counter shaft right side bearing.

11. Install the gear unit. Refer to “Gear Unit” in this section.

D103B765

D103B781

GEAR SHIFT FORK



2. Remove the each shift shaft assembly from the gear unit.

3. Remove the first–second gear shift shaft assembly.

D

Fix the shift shaft assembly to a vise with protector.

D

Remove the first–second gear fork pin using a pin punch and a hammer (1).

D

Remove the first–second gear shift fork (2).

D

Remove the first–second gear shift yoke pin using a pin punch and a hammer (3).

D

Remove the first–second gear shift yoke (4).

Important: Mark the place and direction of shift fork and yoke to install easily before removing them.

D103B783

DAEWOO M-150 BL2

DAEWOO M-150 BL2


4. Disassemble the third–fourth gear shift shaft assembly.

D

Fix the third–fourth gear shift shaft assembly to a vise with protector.

D

Remove the third–fourth gear fork pin using a pin punch and a hammer (1).

D

Remove the third–fourth gear fork (2).

D

Remove the third–fourth gear shift yoke pin using a pin punch and a hammer (3).

D

Remove the third–fourth gear shift yoke (4).

D103B782

D103B784

5. Disassemble the fifth–reverse gear shift shaft assembly.

D

Remove the shift shaft not installed with yoke by pushing (1).

D

Remove the following parts from the reverse shift arm.

a. Fifth–reverse gear ball.

b. Reverse shift guide ball and spring.

D

Fix the shift shaft assembly to a vise with protector.

D

Remove the reverse gear shift arm pin using a pin punch and a hammer (2).

D

Remove the reverse gear shift arm (3).

D

Remove the fifth gear shift yoke pin using a pin punch and a hammer (4).

D

Remove the fifth gear shift yoke (5).

D103B785

Inspection Procedure – Shift Shaft

1. Check for bent, deformed or damaged shift shaft.

2. Replace shift shaft if necessary.

D103B786


Inspection Procedure – Shift Fork

1. Measure the end thickness of shift fork and replace if below limit.

Unit : mm (in.)

Shift fork end

Standard

ÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ thickness (mm)

Limit

ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁ

Low Speed Shift Fork 8.7 (0.343) 8.1 (0.319)

ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁ

High Speed Shift Fork 7.8 (0.307) 7.2 (0.283)

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ

Fifth Gear Shift Fork

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ

7.8 (0.307) 7.2 (0.283)

ÁÁÁÁÁÁÁÁ

D103B787

Low Speed

Shift Shaft

High Speed

Shift Shaft

5th/Reverse

Shift Shaft



Important: Use only new fork fin and yoke pin.

D103B788

DIFFERENTIAL


1. Remove the differential assembly. Refer to “Gear

Unit” in this section.

2. Remove the differential ring gear.

D

Fix the differential assembly to a vise with protector.

D


D

Remove the ring gear (2).

D103B789

3. Remove the pinion gear pin.

D

Remove the pin using a pin punch and a hammer

(1).

D103B790

DAEWOO M-150 BL2

DAEWOO M-150 BL2


4. Remove the pinion gear shaft.

D

Remove the shaft from the case (1).

D103B791

5. Remove the pinion gears and the side gears.

D

Remove the pinion gears and the washers (1).

Important: Remove the pinion gear and the washer by rotating the side gear.

D

Remove the side gears (2).

D

Remove the adjust shims from the side gears (3).

D103B792

6. Remove the differential right side bearing and speedometer drive gear.

D

Remove the right side bearing using the differential bearing puller DW220–020A–01 and the differential bearing plate adapter DW220–020A–02.

D

Remove the speedometer drive gear (1).

D13B793A

7. Remove the differential left side bearing.

D

Remove the left side bearing using the differential bearing puller DW220–020A–01 and the differential bearing plate adapter DW220–020A–03.

D13B794A


D103B795

Side Gear Play Inspection

1. Measure the axle direction play of side gear and replace a side gear washer if it exceeds limit.

UNIT : mm (in.)

Thrust Free Play of 0.05–0.33

Differential Side (0.0020–0.0130)


UNIT : mm (in.)


0.90 (0.0354) 0.95 (0.0374)

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ

Thrust Adjusting

1.00 (0.0394) 1.05 (0.0413)

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

Shim

1.10 (0.0433) 1.15 (0.0453)

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ

1.20 (0.0472)

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ

2. After checking for worn or scratched thrust adjusting shim, replace it if necessary.

a. Side gear.

b. Driver.

D103B796


1. Install the differential left side bearing.

D

Insert the left side bearing (1).

D

Install the left side bearing using the bushing, seal installer 09913–76010 and a hammer.

Important: Coat the inner parts; bearing, washer, shim etc. with gear fluid.

D103B797

2. Install the speedometer drive gear and differential right side bearing.

D

Insert the speedometer drive gear(1).

D

Insert the differential right side bearing (2).

D

Install the right side bearing using the bushing, seal installer 09913–76010 and a hammer.

D103B798

DAEWOO M-150 BL2

DAEWOO M-150 BL2


3. Install the side gears and the pinion gears.

D

Insert the trust adjusting shims to the side gears.

D

Install the side gears (1).

D

Install the pinion gears and washers (2).

Important: Install the pinion gears and washers simultaneously.

D103B799

4. Install the pinion gear shaft and pin.

D

Insert the shaft into the gear pin hole by rotating

(1).

D

Press the pin using a pin punch and a hammer (2).

Important: Use only new pin.

D103B800

5. Install the differential ring gear.

D

Fix the differential assembly to a vise.

D

Install the ring gear with the bolts (1).

Tighten


S m (59–74 lb-ft).

6. Install the differential assembly. Refer to “Gear Unit” in this section.

D13B801A


SPECIFICATIONS

GENERAL SPECIFICATIONS

Application

General

Service

Type

Description

Forward gear

Reverse gear

Unit

–

–

Gear ratio 1st

2nd

3rd

4th

5th

Reverse

Final drive ratio

Fluid capacity

Fluid classification

Key groove width of 1st gear synchronizer ring

2nd, 3rd, 4th gear

5th gear

Shift fork end thickness

Low speed shift fork

(1st~2nd)

High speed shift fork

(3rd~4th)

5th gear shift fork

Clearance between gear and synchronizer ring

Clearance between sleeve and shift fork

–

–

–

L(qt)

–

–

–

–

– mm(in.) mm(in.) mm(in.) mm(in.) mm(in.) mm(in.) mm(in.) mm(in.)

Thrust free play of differential side gear

Speedometer gear ratio(Driven/Drive)

7.8 (0.307)

7.8 (0.307)

1.0 (0.039) mm(in.)

–

0.2 – 0.6

(0.008 – 0.024)

0.05 – 0.33

(0.002 – 0.013)

17/18 (0.944)

Standard

Synchronized mesh type

Sliding mesh type

3.818

2.210

1.423

1.029

0.837

3.583

4.444

2.1 (2.21)

75W-85 (GL-4)

8.2 (0.323)

9.6 (0.378)

9.4 (0.370)

8.7 (0.343)

Limit

–

–

–

–

–

–

–

–

–

–

–

8.6 (0.339)

10.0 (0.394)

9.8 (0.386)

8.1 (0.319)

7.2 (0.283)

7.2 (0.283)

0.5 (0.020)

1.0 (0.039)

–

–

DAEWOO M-150 BL2

Application

5th/Reverse Gear Shift Shaft Bolt

Back Up Light Switch Nut

Counter Shaft 5th Gear Nut

Crankshaft Position Sensor Bolt

Differential Ring Gear Bolt

Engine Mounting Front Bracket Bolt

(Cylinder Block Side)

Engine Mounting Front Damping Bush Bolt

(Crossmember Side)

Engine Mounting Front Damping Bush Bolts

(Crossmember Side)

Engine Mounting Front Damping Bush Bolt/Nut

(Bracket Side)

Front Exhaust Pipe Nut

(Exhaust Manifold Side/Muffler Side)

Gear Shift Control Case Bolt

Gear Shift Lever Bolt

High Speed Shift Shaft Bolt

Low Speed Shift Shaft Bolt

Oil Drain Plug

Oil Level Plug

Radiator Lower Hose Bracket Bolts

Reverse Idle Gear Shaft Bolt

Reverse Shift Lever Bolt

Select Cable Nut(Shift Lever Side)

Select Lever Bolt

Side Cover Plate Screw

Shift Guide Bolt

Shift Interlock Bolt

Side Cover Bolt

Speedometer Driven Gear Bolt

Starter Motor Bolt

Transaxle Case Bolt

Transaxle Case(left) Cap Bolt

Transaxle Lower Bolt and Nut(Engine Side)

Transaxle Mounting Bolt(Body Side)

Transaxle Mounting Bolt and Nut(Transaxle Side)

Transaxle Upper Bolt(Engine Side)

Transaxle Under Cover Bolt


FASTENER TIGHTENING SPECIFICATIONS

N

S

m

10 – 16

15 – 18

60 – 80

5 – 8

80 – 100

35 – 41

35 – 41

45 – 55

68 – 83

25 – 35

6 – 7

18 – 28

18 – 28

8 – 12

4 – 7

18 – 28

15 – 22

8 – 12

55 – 65

45 – 55

55 – 65

55 – 65

35 – 55

18 – 28

4 – 7

10 – 16

10 – 16

25 – 30

36 – 54

8 – 15

18 – 28

18 – 28

8 – 12

18 – 28

Lb-Ft

7 – 12

11 – 13

44 – 59

–

59 – 74

25 – 30

25 – 30

33 – 41

51 – 61

18 – 25

–

13 – 21

13 – 21

–

–

13 – 21

11 – 16

–

41 – 48

33 – 41

41 – 48

41 – 48

25 – 41

13 – 21

–

7 – 12

7 – 12

18 – 22

26 – 40

–

13 – 21

13 – 21

–

13 – 21

Lb-In

–

–

–

44 – 70

–

–

–

–

–

–

53 – 62

–

–

71 – 106

35 – 62

–

–

71 – 106

–

–

–

–

–

–

35 – 62

–

–

–

–

70 – 132

–

–

71 – 106

–

DAEWOO M-150 BL2


SPECIAL TOOLS

SPECIAL TOOLS TABLE

D103B110

09913–76010

Bushing, Seal Installer

D103B106

DW09913–80112

Gear, Bearing Installer

D103B104

DW09921–57810

Gear, Bearing Remover

D103B107

DW09925–98221


D103B105

DW09940–53111


D103B109

DW09943–78210

Bushing, Seal Installer

DW110–021

Engine Assembly

Support Fixture

D103B103

DW220–010A

Transaxle Fixture

D13B101A

DAEWOO M-150 BL2

DAEWOO M-150 BL2

D13B112A

D13B113A


SPECIAL TOOLS TABLE (Cont’d)

DW220–020A–01

Differential Bearing

Puller

DW220–020A–02


Plate Adapter

DW220–031

Transaxle Remove/

Install Support

D103B102

D103B108

KM466–A

Gear, Bearing Remover

/ Installer

DW220–020A–03


Plate Adapter

KM519

Oil Seal Installer

D13B114A D103B111

SECTION 5C

CLUTCH

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted.

TABLE OF CONTENTS

Description and Operation . . . . . . . . . . . . . . . . . . 5C-2

Driving Members . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2

Driven Members . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Members . . . . . . . . . . . . . . . . . . . . . . .

5C-2

5C-2

Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 5C-3

Clutch Components . . . . . . . . . . . . . . . . . . . . . . . . 5C-3

Diagnostic Information and Procedures . . . . . 5C-4

General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4

Clutch Pedal Operation

Clutch Cable Adjustment

. . . . . . . . . . . . . . . . . . . . 5C-5

. . . . . . . . . . . . . . . . . . . 5C-5

Repair Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6

On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6

Pressure Plate, Clutch Disc and

Input Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . 5C-6

Clutch Release Bearing, Shaft and Bushing . . . 5C-8

Clutch Release Arm . . . . . . . . . . . . . . . . . . . . . . 5C-10

Clutch Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-11

Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-12

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Specifications . . . . . . . . . . . . . . . . . . . .

5C-13

5C-13

Fastener Tightening Specifications . . . . . . . . . . 5C-13

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools Table . . . . . . . . . . . . . . . . . . . . . . .

5C-14

5C-14

DAEWOO M-150 BL2

5C – 2 CLUTCH

DESCRIPTION AND OPERATION

DRIVING MEMBERS

The driving members consist of two flat surfaces machined to a smooth finish. One of these is the rear face of the engine flywheel, and the other is the pressure plate. The pressure plate is fitted into a steel cover, which is bolted to the flywheel.

The driving and driven members are held in contact by spring pressure. This pressure is exerted by a diaphragm spring in the pressure plate assembly.

DRIVEN MEMBERS

The driven member is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the input shaft, but which drives the input shaft through these same splines.

OPERATING MEMBERS

The clutch release system consists of the clutch pedal, the clutch release shaft, the clutch cable, the release arm and the release bearing. When pressure is applied to the clutch pedal, the clutch release shaft pushes against the release bearing by rotating. The bearing then pushes against the diaphragm spring in the pressure plate assembly, thereby releasing the clutch.

DAEWOO M-150 BL2

COMPONENT LOCATOR

CLUTCH COMPONENTS

CLUTCH 5C – 3

1 Clutch Disc

2 Pressure Plate

3 Release Bearing

4 Release Shaft

5 Release Shaft Bushing (No.1)

6 Release Shaft Bushing (No.2)

7 Release Shaft Seal

8 Release Arm

9 Clutch Cable Adjusting Nut

10 Clutch Cable

11 Clutch Pedal

D13C4011

DAEWOO M-150 BL2

5C – 4 CLUTCH

DIAGNOSTIC INFORMATION AND PROCEDURES

GENERAL DIAGNOSIS

Condition

Slipping Clutch

Dragging Clutch

Fails to Release

Pedal Stays on Floor

When Disengaged

Clutch Vibration

Clutch Noise

Grabbing Clutch

Probable Cause

D

Improper clutch cable adjustment.

D

Worn or oily contamination on clutch disc surface.

D

Worn or oily contamination on pressure plate, flywheel surface.

D

Damaged or weakened diaphragm spring.

D

Rusted clutch cable.

D


D

Worn or weakened diaphragm spring.

D

Worn or rusted splines of input shaft or clutch disc.

Correction

D


D


D

D

D

Replace pressure plate, flywheel.


D

Replace clutch cable.

D


D


Replace input shaft or clutch disc.

D

Excessively wobbly clutch disc.

D

Worn clutch disc.

D

Bent or damaged clutch disc.

D

Worn or rusted splines of input shaft or clutch disc.

D

Improper operation of clutch release shaft.

D

Replace clutch release shaft.

D

Interfered clutch release bearing.

D

Lubricate and adjust clutch release bearing.

D

Weakened diaphragm spring.

D

Clutch facing with oily contamination.

D

Release bearing slides unsmoothly on input shaft bearing retainer.

D


D


D

Lubricate retainer release bearing.

D

Wobbly clutch disc or poor facing contact.

D

Loose clutch disc rivets.

D

Weakened clutch disc torsion spring.

D

Distorted pressure plate or flywheel surface.

D

Weakened engine mounting or loosened installing bolt or nut.

D

D

D

D

D


D


D


D

Replace pressure plate or flywheel.

D




Replace input shaft or clutch disc.

Retighten or replace mounting.

D

Worn or broken release bearing.

D

Worn input shaft bearing.

D

Cracked clutch disc.

D

Pressure plate and diaphragm spring rattling.

D


D

Clutch disc facing with oily contamination.

D

Excessively worn on clutch disc facing.

D

Rivet head showing out of facing.

D

Weakened clutch torsion spring.

D

Replace release bearing.

D

Replace input shaft bearing.

D


D


D

D


D


D


D



DAEWOO M-150 BL2

CLUTCH PEDAL OPERATION

CLUTCH 5C – 5

CLUTCH CABLE ADJUSTMENT

D103C301

Clutch pedal free travel

It is designed that there is no clutch pedal free travel.

Clutch pedal travel (A)

ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ

Pedal Travel 100–110 mm (3.9–4.3 in.)



Clearance between pedal and floor just before clutch connection (B)

After starting the engine, check if the clearance between pedal and floor is within specified range in condition of idling, lifting, parking brake and drawing out clutch pedal.

ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clearance Between Pedal and Floor 30–40 mm just Before Clutch Connection (1.2–1.6 in.)

ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Caution: During inspection, take care on sudden departure.

DAEWOO M-150 BL2

D103C302

If clutch connection / disconnection is operated unsmoothly, adjust the clutch cable by adjusting clutch cable adjust nut.

5C – 6 CLUTCH

INSTRUCTION REPAIR

ON–VEHICLE SERVICE

D13B5151

PRESSURE PLATE, CLUTCH DISC

AND INPUT SHAFT BEARING

Tools Required

09917–58010 Input Shaft Bearing Remover

09924–17810 Flywheel Holder

09925–98210 Input Shaft Bearing Installer

DW110–021 Engine Fixture

DW210–010 Clutch Center Guide


1. Remove the transaxle from the vehicle. Refer to Sec-

tion 5B, Manual Transaxle.

2. Support the engine to normal position using the engine fixture DW110–021.

Notice: The abnormal position of the engine may damage to the related parts and interfere with them. You must support the engine to normal position after removing the transaxle.

D103B516

3. Remove the pressure plate and the clutch disc.

D

Fix the fly wheel using the fly wheel holder 09924–

17810.

D

Remove the pressure plate bolts (1).

D

Remove the pressure plate and the clutch disc (2).

D13C5021

DAEWOO M-150 BL2

DAEWOO M-150 BL2

CLUTCH 5C – 7

4. Remove the transaxle input shaft bearing using the input shaft bearing remover 09917–58010, the flywheel holder 09924–17810 and a spanner.

D13C5031

Inspection Procedure – Pressure Plate and Clutch Disc

1. Pressure plate inspection .

D

Check the weak and damaged diaphragm spring

(1).

D

Check the polluted face by the oil, grease (2).

D13C5041

2. Clutch disc inspection

D

Measure rivet head depth from clutch disc surface and replace if below limit.

Unit : mm (in.)

ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

Standard

ÁÁÁÁÁÁ

Limit

Rivet Head Depth


1.2 (0.047) 0.5 (0.02)

ÁÁÁÁÁÁÁ

D

Replace the clutch disc if clutch disc surface is contaminated or clutch disc rivets are loosen.

D103C505

3. Clutch disc runout in rotational direction inspection.

D

Measure runout in rotational direction and replace if runout exceeds limit.

Unit : mm (in.)

Disc Runout Limit in Rotational

ÁÁÁÁÁÁ 0.7 (0.028)

Direction (Periphery)

ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ

D103C506

5C – 8 CLUTCH



2. Install the input shaft bearing using the input shaft bearing installer 09925–98210 and the flywheel holder 09924–17810.

D13C5071

3. Install the pressure plate and the clutch disc.

D

Install the clutch disc.

D

Install the pressure plate (1).

D

Align the pressure plate and the clutch disc onto the flywheel using the clutch center guide DW210–010 and the flywheel holder 09924–17810.

D

Install the pressure plate bolts.

Tighten


S m (13–21 lb-ft).

D13C508B

D103C509

CLUTCH RELEASE BEARING, SHAFT

AND BUSHING

Tools Required

09923–46040 Bushing Joint Pipe

09925–48220 Bushing Remover/Installer

09930–30102 Sliding Shaft

09943–88211 Bushing, Bearing Installer


1. Remove the transaxle from the vehicle. Refer to Sec-

tion 5B, Manual Transaxle.

2. Remove the release arm. Refer to “Clutch Release

Arm” in this section.

3. Remove the release bearing.

4. Remove the release shaft and bushing.

D

Remove the bushing (No.2) and seal using the bushing remover 09925–48220 and hammer.

D

Remove the release shaft (1).

D103C510

DAEWOO M-150 BL2

DAEWOO M-150 BL2

CLUTCH 5C – 9

D

Insert the tap (M14X1.5) to the busing (No.1) (2).

D103C511

D

Insert the bushing joint pipe 09923–46040 to the tab.

D

Connect the sliding shaft 09930–30102 to the end of the bushing joint pipe 09923–46040.

D

Remove the bushing (No.1) by pulling.

D13C512A

Inspection Procedure – Release Bearing and Shaft

1. Release bearing inspection

D

Check for noisy, worn and damaged release bearing.

D

Check for a grabbing rotation of release bearing.

D

Replace the release bearing if necessary.

D103C513

2. Release shaft inspection

D

Check for a warped shaft (1).

D

Check for a worn fork (2).

D

Replace the shaft if necessary.

D103C514

5C – 10 CLUTCH



2. Install the release shaft bushing (No.1) using the bushing joint pipe 09923–46040, bushing, bearing installer 09943–88211 and a hammer.

D103C515

3. Install the release shaft bushing (No.2) and seal using the bushing remover/installer 09925–48220 and a hammer.

D103C516

4. Install the release bearing.

D

Coat the spline of transaxle input shaft with multi– purpose grease (1).

D

Coat the release bearing bore and the connecting of release shaft with multi–purpose grease (2).

D

Install the release bearing.

D103C517

CLUTCH RELEASE ARM


1. Disconnect the clutch cable.

D

Remove the adjusting nut (1).

D


D103C518

DAEWOO M-150 BL2

DAEWOO M-150 BL2

CLUTCH 5C – 11

2. Remove the clutch release arm.

D

Remove the bolt and nut (1).

D

Remove the release arm (2).

D103C519



2. Install the clutch release arm.

D

Install the clutch release arm matching to punched mark (1).

Tighten

Tighten the bolt and nut to 10–16 N

S m (7.5–12 lb-ft).

3. Adjust the clutch cable. Refer to “Diagnosis” in this section.

D13C520A

D103B506

CLUTCH CABLE


Drive Similar)


1. Disconnect the clutch cable from the transaxle.

D

Remove the adjusting nut (1).

D

Disconnect the cable from the wire clip (2).

D

Pull and remove the cable from the transaxle mount hole (3).

2. Disconnect the clutch cable from the pedal.

D

Pull upward and disconnect the cable from the pedal hook (1).

D13C5211

5C – 12 CLUTCH

3. Remove the battery. Refer to Section 1E, Engine

Electrical.

4. Remove the clutch cable.

D

Remove the nuts (1).

D

Remove the cable grommet (2).

D

Remove the cable from the pedal (3).

D103C522


1. Install the clutch cable.

2 Install the battery.

3. Connect the clutch cable to the pedal.

4. Connect the clutch cable to the transaxle.


D103C302

D103C524

CLUTCH PEDAL


Drive Similar)


1. Disconnect the clutch cable. Refer to “Clutch Cable” in this section.

2. Remove the clutch pedal.

D

Release the pedal return spring.

D

Remove the nut (1).

D

Remove the clutch pedal (2).

D

Remove the bushing (3).

D

Remove the pedal return spring (4).


1. Install the pedal return spring.

2. Install the bushings.

3. Install the clutch pedal.

4. Install the nut.

5. Fix the pedal return spring.

6. Connect the clutch cable.


D103C302

DAEWOO M-150 BL2

CLUTCH 5C – 13

SPECIFICATIONS

GENERAL SPECIFICATIONS

Application Description Unit Standard Limit

ÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

Type – Single Dry Plate –

ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

Outside Diameter mm (in.) 170 (6.7) –

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clutch Disc

Inside Diameter mm (in.) 110 (4.3) –


Thickness mm (in.) 7.15 (0.281) –


Rivet Head Depth mm (in.) 1.2 (0.047) 0.5 (0.020)


Disc Runout Limit in Rotational Direction mm (in.) – 0.7 (0.028)


Pedal Free Travel mm (in.) 0 (0) –


100 – 110

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Pedal Travel mm (in.)

ÁÁÁÁÁÁ

(3.9 – 4.3)

–


Clearance between pedal and floor just 30 – 40

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ before clutch connection mm (in.) –

(1.2 – 1.6)

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

FASTENER TIGHTENING SPECIFICATIONS

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Application N

S

m Lb-Ft Lb-In

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Pressure Plate Bolt 18 – 28 13 – 21 –

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clutch Release Arm Bolt and Nut 10 – 16 7.5 – 12 –

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

DAEWOO M-150 BL2

5C – 14 CLUTCH

SPECIAL TOOLS

SPECIAL TOOLS TABLE

D103C101

09917–58010

Input Shaft Bearing

Remover

D103C106

09930–30102

Sliding Shaft

09923–46040

Bushing Joint Pipe

09943–88211

Bushing, Bearing

Installer

D103C105

D103C107

09924–17810

Fly Wheel Holder

DW110–021

Engine Assembly

Support Fixture

D102B116 D103B103

09925–48220

Bushing Remover/

Installer

DW210–010

Clutch Center Guide

D103C104 D103C103

09925–98210

Input Shaft Bearing

Installer

D103C102

DAEWOO M-150 BL2

5 Transaxle – Daewoo Matiz Service Manual

SECTION 5B

FIVE-SPEED MANUAL TRANSAXLE

TABLE OF CONTENTS

5B – 2 FIVE-SPEED MANUAL TRANSAXLE

DESCRIPTION AND OPERATION

FIVE-SPEED MANUAL TRANSAXLE

REVERSE GEAR MISSHIFT

PREVENTING MECHANISM

DIFFERENTIAL

FIVE-SPEED MANUAL TRANSAXLE 5B – 3

COMPONENT LOCATORS

GEAR SHIFT CONTROL

5B – 4 FIVE-SPEED MANUAL TRANSAXLE

INPUT SHAFT AND COUNTER SHAFT GEAR

FIVE-SPEED MANUAL TRANSAXLE 5B – 5

5B – 6 FIVE-SPEED MANUAL TRANSAXLE

GEAR SHIFT FORK

FIVE-SPEED MANUAL TRANSAXLE 5B – 7

DIFFERENTIAL AND CASE

5B – 8 FIVE-SPEED MANUAL TRANSAXLE

DIAGNOSTIC INFORMATION AND PROCEDURE

GENERAL DIAGNOSIS

CHECKING FLUID LEVEL

CHANGING FLUID

FIVE-SPEED MANUAL TRANSAXLE 5B – 9

CHECKING TRANSAXLE NOISE

CHECKING BEARING NOISE

5B – 10 FIVE-SPEED MANUAL TRANSAXLE

REPAIR INSTRUCTION

ON–VEHICLE SERVICE

MANUAL TRANSAXLE ASSEMBLY

FIVE-SPEED MANUAL TRANSAXLE 5B – 11

5B – 12 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 13

5B – 14 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 15

5B – 16 FIVE-SPEED MANUAL TRANSAXLE

GEAR SHIFT CONTROL CASE

ASSEMBLY

FIVE-SPEED MANUAL TRANSAXLE 5B – 17

5B – 18 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 19

SPEEDOMETER DRIVEN GEAR AND

CABLE

Caution: Be careful to prevent personal injury while the exhaust pipe is hot.

5B – 20 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 21

GEAR SHIFT CONTROL CABLE

5B – 22 FIVE-SPEED MANUAL TRANSAXLE

GEAR SHIFT CONTROL LEVER

FIVE-SPEED MANUAL TRANSAXLE 5B – 23

5B – 24 FIVE-SPEED MANUAL TRANSAXLE

MAINTENANCE AND REPAIR

UNIT REPAIR

GEAR UNIT

FIVE-SPEED MANUAL TRANSAXLE 5B – 25

5B – 26 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 27

5B – 28 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 29

5B – 30 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 31

5B – 32 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 33

5B – 34 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 35

5B – 36 FIVE-SPEED MANUAL TRANSAXLE

INPUT SHAFT

FIVE-SPEED MANUAL TRANSAXLE 5B – 37

5B – 38 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 39

5B – 40 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 41

COUNTER SHAFT

5B – 42 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 43

5B – 44 FIVE-SPEED MANUAL TRANSAXLE

FIVE-SPEED MANUAL TRANSAXLE 5B – 45

5B – 46 FIVE-SPEED MANUAL TRANSAXLE