2003 DAEWOO MATIZ clutch

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.

5B–12 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B510
12. Remove the transaxle upper bolts.
a. Exhaust manifold side bolt.
b. Thermostat housing side bolt.
D103B505
13. Remove the transaxle under cover.

Remove the bolts (1).

Remove the transaxle under cover (2).
14. Remove the front tires and wheels.
D103B506
15. Drain the transaxle fluid.

Remove the drain plug and drain the fluid.
16. Disconnect the clutch cable.

Remove the cable adjust nut (1).

Disconnect the cable from the wire clip (2).

Disconnect the cable from the transaxle mount
hole (3).
D103B509
17. Remove the front under longitudinal frames and sta-
bilizer. 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.

Remove the bolts (1).

Remove the lower plate (2).

5B–16 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B5032
8. Install the radiator lower hose and crank position
(CKP) sensor.
Tighten
Tighten the radiator lower hose bolt to 8–15 Nm
(70–132 lb-in).
Tighten the CKP sensor bolt to 5–8 Nm (44–70 lb-
in).
D13B520A
9. Refill the transaxle fluid.

Tighten the drain plug to 25–30 Nm (18–22 lb-ft)
(a).

Remove the oil level plug (1).

Refill recommended fluid to the proper level.
Classification 75W – 85 (GL–4) Capacity2.1L (2.21 qt)

Tighten the oil level plug to 36–54 Nm (26–40 lb-ft)
(b).
D13B521A
10. Adjust the clutch cable. Refer to Section 5C, Clutch.

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
Nm (25–41 lb-ft).
D103B501
GEAR SHIFT CONTROL CASE
ASSEMBLY
Removal Procedure
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.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and the shift control cable
(3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.

5B–22 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B540
Installation Procedure
1. Install in the reverse order of removal.
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.
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.

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

Install the selector lever control cable clip (2).

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

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 Nm
(71–106 lb-in).
D103B543
GEAR SHIFT CONTROL LEVER
Removal Procedure
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.

Remove the bolts (1).

Remove the gear shift control lever assembly (2).

Remove the gear shift lever sensor connector.
(If equipped with auto clutch).

5B–24 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
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 us-
ing the transaxle fixture DW220–010.
D13B7021
3. Remove the related clutch parts. Refer to Section 5C,
Clutch.
4. Remove the manual transaxle mounting bracket.

Remove the bolts (1).

Remove the nut (2).

Remove the mounting bracket (3).
D103B703
5. Disconnect the backup light switch and speedometer
driven gear assembly.

Remove the nut (1).

Disconnect the backup light switch (2).

Remove the bolt (3).

Remove the speedometer driven gear assembly
(4).

5B–28 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B716
17. Remove the transaxle case (Left).

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

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

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

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

Remove the sealant on the case.
D103B717
18. Remove the reverse gear shift lever.

Remove the bolts (1).

Remove the reverse gear shift lever (2).
D103B718
19. Remove the reverse idle gear shaft assembly.

Push the reverse idle gear toward inner case.

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

Remove the reverse idle gear from the shaft.
D103B719
20. Remove the fifth–reverse gear shift shaft.
a. Fifth–reverse gear shift shaft.

5B–32 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B731A
8. Install the shift shaft ball and spring.

Install the third–fourth gear shift shaft ball and
spring.
Tighten
Tighten the bolt to 10–16 Nm (7–12 lb-ft) (a).

Install the fifth–reverse gear shift shaft ball and
spring.
Tighten
Tighten the bolt to 10–16 Nm (7–12 lb-ft) (b).
Important: Install the fifth–reverse gear shift shaft
spring marked when removing.
D13B732A
9. Install the transaxle left side case.

Coat the transaxle case with recommended seal-
ant.
Transaxle Case Sealant THREE BOND 1215

Install the transaxle left side case to the transaxle
right side case.
Tighten
Tighten the bolts to 15–22 Nm (11–16 lb-ft) (a).

Tighten the bolts (8), stud bolts (3) if equipped with
auto clutch.
Tighten the bolts to 15–22 Nm (11–16 lb-ft) (b).
D13B733A
10. Install the first–second gear shift shaft ball and
spring.
Tighten
Tighten the bolt to10–16 Nm (7–12 lb-ft) (a).
11. Install the reverse idle gear shaft bolt.
Tighten
Tighten the bolt to 18–28 Nm (13–21 lb-ft) (b).
D103B734
12. Install the counter shaft bearing outer race.

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.

5B–36 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B744A
24. Install the backup light switch and the speedometer
driven gear assembly.

Install the backup light switch (1).
Tighten
Tighten the nut to 15–18 Nm (11–13 lb-ft) (a).

Install the speedometer driven gear assembly
(2).
Tighten
Tighten the bolt to 4–7 Nm (35–62 lb-in) (b).

Install the hydraulic pump assembly (If equipped
with auto clutch). Refer to Section 5D, Auto
Clutch.
D13B7452
25. Install the transaxle mount.

Install the mount (1).
Tighten

Tighten the bolts to 55–65 Nm (41–48 lb-ft) (a).

Tighten the nut to 55–65 Nm (41–48 lb-ft) (b).
D13B701A
26. Install the related clutch parts. Refer to Section 5C,
Clutch.
27. Remove the transaxle assembly from transaxle
stand.

Remove the transaxle assembly using the trans-
axle fixture DW220–010A.
28. Install the transaxle assembly. Refer to “Manual
Transaxle Assembly” in this section.
D103B746
INPUT SHAFT
Tools Required
DW09921–57810 Gear, Bearing Remover
DW09925–98221 Gear, Bearing Installer
DW09940–53111 Gear, Bearing Installer
Disassembly Procedure
1. Remove the gear unit. Refer to “Gear Unit” in this
section.
2. Remove the input shaft right side bearing.

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

Remove the bearing by pressing (1).