2003 DAEWOO MATIZ differential

5B–8 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURE
GENERAL DIAGNOSIS
ConditionProbable CauseCorrection
Gear Slipping Out of Mesh
Worn shift fork.
Replace shift fork.

Worn synchronizer sleeve or gear.
Replace sleeve or gear.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Weakened or damaged location
spring.
Replace spring.

Loose or damaged synchronizer
spring.
Replace synchronizer spring.

Excessive back-lash of gear.
Adjust back-lash of gear.
Gear Catching
Bent or distorted shift shaft or shift
fork.
Replace shift shaft or shift fork.

Weakened or damaged
synchronizer spring.
Replace spring.
Hard Shifting
Worn synchronizer ring.
Replace synchronizer ring.

Worn synchronizer sleeve or gear.
Replace sleeve or gear.

Bent or distorted shift shaft.
Replace shift shaft.

Excessive free travel of all gears
in axial direction.
Replace gear.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Poor adjustment of clutch cable.
Adjust clutch cable.

Distorted or broken clutch disc.
Replace clutch disc.

Damaged pressure plate.
Replace pressure plate.
Noise in the Neutral Gear
Insufficient lubricant.
Supply lubricant.

Worn input shaft gear.
Replace gear.

Worn bearings on the input shaft
gears.
Replace bearing.

Worn clutch release bearing.
Replace clutch release bearing.
Noise in the All Gears
Insufficient lubricant.
Supply lubricant.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Worn input shaft or counter shaft
gear.
Replace gear.

Worn or damaged synchronizer
ring.
Replace synchronizer ring.

Worn or damaged synchronizer
sleeve.
Replace synchronizer sleeve.

Worn differential gear or bearing.
Replace gear or bearing.
Noise in the Peculiar Gear
Worn or damaged synchronizer
ring in the peculiar gear.
Replace synchronizer ring.

Worn or damaged gear in the
peculiar gear.
Replace gear.

Worn or damaged bearing in the
peculiar gear.
Replace bearing.
Leak of Lubricant
Damaged gasket, oil seal or
O-ring.
Replace gasket, oil seal or O-ing.

FIVE-SPEED MANUAL TRANSAXLE 5B–9
DAEWOO M-150 BL2
CHECKING FLUID LEVEL
Check for a leak in the area of transaxle case and seal-
ing and then check fluid level and condition after remov-
ing 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
75W-85(GL-4)
Fluid Capacity2.1L(2.21qt)
Service intervalRefer 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 re-
pair 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 lubri-
cants 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 oper-
ates in.

Drive – Under a light acceleration or a heavy pull.

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

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

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 pre-
loaded, a differential side bearing noise should not di-
minish 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 con-
siderably when the wheels are off the ground.

FIVE-SPEED MANUAL TRANSAXLE 5B–29
DAEWOO M-150 BL2
D103B720
21. Remove the gear unit.

Remove the gear unit and the shift shaft assem-
bly together (1).
Notice: Be careful not to damage teeth of the counter
shaft pinion and the differential ring gear.

Remove the high and the low speed shift shaft
assembly from the gear unit.
D103B721
22. Remove the differential assembly.

Insert a wooden stick into the lower side of differ-
ential (1).

Remove the differential assembly by moving it
right and left (2).
D103B722
23. Remove the related parts of the transaxle case (Left
Side).

Remove the bolt (1).

Remove the oil gutter (2).

Remove the bolts (3).

Remove the oil plate (4).

Remove the differential left side oil seal using a
hammer and a copper chisel (5).
D103B723

Remove the bolts (6).

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

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

Remove the oil level plug (including steel gasket)
(9).

Remove the counter shaft bearing outer race us-
ing a hammer and the gear, bearing installer DW
09940–53111.

5B–30 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B724
24. Remove the related parts of the transaxle case
(Right Side).

Remove the input shaft oil seal using a screwdriv-
er (1).

Remove the differential left side oil seal using a
hammer and a copper chisel (2).
D103B725
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.)

Clearance Between
Standard Limit

Clearance Between
Sleeve and Shift
Fork
0.2 ∼0.6
(0.008∼0.024)1.0
(0.039)
D103B726
Assembly Procedure
1. Install the related parts of the transaxle case (Right
Side).

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

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.
D13B727A
2. Install the related parts of the transaxle case (Left
Side).

Install the oil plate with the bolts.

Install the oil gutter with the bolt.

Install the oil level plug (including steel gasket).
a. Oil level plug.
Tighten
Tighten the oil level plug to 36–54 Nm (26–40 lb-ft).

Install the left side case cap with the bolts (includ-
ing O–ring) (1).

FIVE-SPEED MANUAL TRANSAXLE 5B–31
DAEWOO M-150 BL2
D13B727A
Tighten
Tighten the bolt to 8–12 Nm (71–106 lb-in).
b. Case cap retaining bolt.

Install the differential left side oil seal using the oil,
seal installer KM519.
D103B728
3. Install the differential assembly to the right side of
transaxle case.
a. Differential assembly.

When the differential ring gear surface is lower
than the right side of transaxle case surface, it is
installed correctly.
D103B729
4. Install the low and the high speed shift shaft assem-
bly to the gear unit.
5. Install the gear unit.

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.
D13B730A
6. Install the fifth–reverse gear shift shaft.
7. Install the reverse idle gear shaft assembly and the
reverse gear shift lever.

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).

Install the reverse gear shift lever (2).
Tighten
Tighten the bolts to 18–28 Nm (13–21 lb-ft).

FIVE-SPEED MANUAL TRANSAXLE 5B–41
DAEWOO M-150 BL2
D103B762
6. Install the input shaft fourth gear bearing and the
fourth gear.
a. Fourth gear.
b. Fourth gear bearing.
D103B763
7. Install the input shaft left side bearing and the fifth
gear spacer.

Install the following parts using the gear, bearing
installer DW09925–98221 and a hammer.
a. Fifth gear spacer.
b. Input shaft left side bearing.
D103B764
8. Install the input shaft right side bearing.

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 sec-
tion.
D103B765
COUNTER SHAFT
Tools Required
09913–76010 Bushing, Seal Installer
DW09913–80112 Gear, Bearing Installer
DW09921–57810 Gear, Bearing Remover
DW09925–98221 Gear, Bearing Installer
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

5B–48 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B787
Inspection Procedure – Shift Fork
1. Measure the end thickness of shift fork and replace if
below limit.
Unit : mm (in.)


Shift fork end
thickness (mm)
Standard
Limit
Low Speed Shift Fork8.7 (0.343)8.1 (0.319)
High Speed Shift Fork7.8 (0.307)7.2 (0.283)
Fifth Gear Shift Fork7.8 (0.307)7.2 (0.283)
D103B788
Low Speed
Shift ShaftHigh Speed
Shift Shaft5th/Reverse
Shift Shaft
Assembly Procedure
1. Install in the reverse order of removal.
Important: Use only new fork fin and yoke pin.
D103B789
DIFFERENTIAL
Disassembly Procedure
1. Remove the differential assembly. Refer to “Gear
Unit” in this section.
2. Remove the differential ring gear.

Fix the differential assembly to a vise with protec-
tor.

Remove the bolts (1).

Remove the ring gear (2).
D103B790
3. Remove the pinion gear pin.

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

FIVE-SPEED MANUAL TRANSAXLE 5B–49
DAEWOO M-150 BL2
D103B791
4. Remove the pinion gear shaft.

Remove the shaft from the case (1).
D103B792
5. Remove the pinion gears and the side gears.

Remove the pinion gears and the washers (1).
Important: Remove the pinion gear and the washer by
rotating the side gear.

Remove the side gears (2).

Remove the adjust shims from the side gears (3).
D13B793A
6. Remove the differential right side bearing and
speedometer drive gear.

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

Remove the speedometer drive gear (1).
D13B794A
7. Remove the differential left side bearing.

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