Page 679 of 1184
5B–54 FIVE-SPEED MANUAL TRANSAXLE
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
Gear, Bearing Installer
D103B105
DW09940–53111
Gear, Bearing Installer
D103B109
DW09943–78210
Bushing, Seal Installer
D103B103
DW110–021
Engine Assembly
Support Fixture
D13B101A
DW220–010A
Transaxle Fixture
Page 682 of 1184
5C – 2 CLUTCH
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRIVING MEMBERS
The driving members consist of two flat surfaces ma-
chined 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.
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.The driving and driven members are held in contact by
spring pressure. This pressure is exerted by a dia-
phragm spring in the pressure plate assembly.
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 pres-
sure plate assembly, thereby releasing the clutch.
Page 684 of 1184
5C –4 CLUTCH
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
ConditionProbable CauseCorrection
Slipping ClutchImproper clutch cable adjustment.Adjust clutch cable.
Worn or oily contamination on clutch disc
surface.Replace clutch disc.
Worn or oily contamination on pressure
plate, flywheel surface.Replace pressure plate, flywheel.
Damaged or weakened diaphragm spring.Replace pressure plate.
Rusted clutch cable.Replace clutch cable.
Dragging ClutchImproper clutch cable adjustment.Adjust clutch cable.
Worn or weakened diaphragm spring.Replace pressure plate.
Worn or rusted splines of input shaft or
clutch disc.Replace input shaft or clutch disc.
Excessively wobbly clutch disc.Replace clutch disc.
Worn clutch disc.Replace clutch disc.
Fails to ReleaseBent or damaged clutch disc.Replace clutch disc.
Worn or rusted splines of input shaft or
clutch disc.Replace input shaft or clutch disc.
Improper operation of clutch release shaft.Replace clutch release shaft.
Pedal Stays on Floor
When DisengagedInterfered clutch release bearing.Lubricate and adjust clutch release
bearing.
Weakened diaphragm spring.Replace pressure plate.
Clutch VibrationClutch facing with oily contamination.Replace clutch disc.
Release bearing slides unsmoothly on input
shaft bearing retainer.Lubricate retainer release bearing.
Wobbly clutch disc or poor facing contact.Replace clutch disc.
Loose clutch disc rivets.Replace clutch disc.
Weakened clutch disc torsion spring.Replace clutch disc.
Distorted pressure plate or flywheel
surface.Replace pressure plate or flywheel.
Weakened engine mounting or loosened
installing bolt or nut.Retighten or replace mounting.
Clutch NoiseWorn or broken release bearing.Replace release bearing.
Worn input shaft bearing.Replace input shaft bearing.
Cracked clutch disc.Replace clutch disc.
Pressure plate and diaphragm spring
rattling.Replace pressure plate.
Improper clutch cable adjustment.Adjust clutch cable.
Grabbing ClutchClutch disc facing with oily contamination.Replace clutch disc.
Excessively worn on clutch disc facing.Replace clutch disc.
Rivet head showing out of facing.Replace clutch disc.
Weakened clutch torsion spring.Replace clutch disc.
Page 685 of 1184
CLUTCH 5C–5
DAEWOO M-150 BL2
CLUTCH PEDAL OPERATION
D103C301
Clutch pedal free travel
It is designed that there is no clutch pedal free travel.
Clutch pedal travel (A)
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 ped-
al.
Clearance Between Pedal and Floor
just Before Clutch Connection
30–40 mm
(1.2–1.6 in.)
Caution: During inspection, take care on sudden
departure.
CLUTCH CABLE ADJUSTMENT
D103C302
If clutch connection / disconnection is operated un-
smoothly, adjust the clutch cable by adjusting clutch
cable adjust nut.
Page 686 of 1184
5C –6 CLUTCH
DAEWOO M-150 BL2
INSTRUCTION REPAIR
ON–VEHICLE SERVICE
D13B5151
D103B516
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
Removal Procedure
1. Remove the transaxle from the vehicle. Refer to Sec-
tion 5B, Manual Transaxle.
2. Support the engine to normal position using the en-
gine fixture DW110–021.
Notice: The abnormal position of the engine may dam-
age to the related parts and interfere with them. You
must support the engine to normal position after remov-
ing the transaxle.
D13C5021
3. Remove the pressure plate and the clutch disc.
Fix the fly wheel using the fly wheel holder 09924–
17810.
Remove the pressure plate bolts (1).
Remove the pressure plate and the clutch disc (2).
Page 692 of 1184
5C –12 CLUTCH
DAEWOO M-150 BL2
D103C522
3. Remove the battery. Refer to Section 1E, Engine
Electrical.
4. Remove the clutch cable.
Remove the nuts (1).
Remove the cable grommet (2).
Remove the cable from the pedal (3).
D103C302
Installation Procedure
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.
5. Adjust the clutch cable. Refer to “Diagnosis” in this
section.
D103C524
CLUTCH PEDAL
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the clutch cable. Refer to “Clutch Cable”
in this section.
2. Remove the clutch pedal.
Release the pedal return spring.
Remove the nut (1).
Remove the clutch pedal (2).
Remove the bushing (3).
Remove the pedal return spring (4).
D103C302
Installation Procedure
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.
7. Adjust the clutch cable. Refer to “Diagnosis” in this
section.
Page 694 of 1184
5C –14 CLUTCH
DAEWOO M-150 BL2
SPECIAL TOOLS
SPECIAL TOOLS TABLE
D103C101
09917–58010
Input Shaft Bearing
Remover
D103C105
09923–46040
Bushing Joint Pipe
D102B116
09924–17810
Fly Wheel Holder
D103C104
09925–48220
Bushing Remover/
Installer
D103C102
09925–98210
Input Shaft Bearing
Installer
D103C106
09930–30102
Sliding Shaft
D103C107
09943–88211
Bushing, Bearing
Installer
D103B103
DW110–021
Engine Assembly
Support Fixture
D103C103
DW210–010
Clutch Center Guide
Page 706 of 1184
POWER STEERING GEAR 6C–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER RACK AND PINION STERING GEAR
ConditionProbable CauseCorrection
Hissing NoiseLoose steering coupling joints.Tighten the steering coupling
joints.
Improperly contacted the power
steering hose with other
components.Fit the power steerng hose into
the hose clips correctly.
Rattling Noise in Steering GearImproperly contacted the power
steering line with the body.Fix the steering line correctly.
Insufficient lubricant.Lubricate the steering gear.
Loose steering gear mounting.Tighten the steering gear
mounting bracket bolts.
Improperly installed tie rod ends.Tighten the tie rod joints and
replace the tie rod end as needed.
Poor Return of Steering Wheel
to CenterImproperly contacted the steering
wheel with the turn signal housing.Adjust the turn signal housing.
Improper binding or looseness of
steering coupling.Replace the intermediate shaft.
Stuck and improperly aligned
power steering pump flow control
valve.Replace the power steering pump.
Improper binding or looseness of
tie rods and ball joints.Tighten the tie rods and the ball
joints. Replace the tie rods and
the ball joints as needed.
Poor adjustments of the steering
gear.Perform a straight-ahead check.
Momentary Increase in Effect
When Turning the WheelInternal leaks of the power
steering pump.Replace the power steering pump.
QuicklyThe damage or restricted flow of
the hoses.Replace the power steering hoses
and pipes.
Insufficient power steering fluid.Fill the power steering fluid
reservoir.
Stuck and improperly operated
power steering pump flow control
valve.Replace the power steering pump.
Steering Surges or Jerks When
Turning with Engine RunningInsufficient pressure of the power
steering pump.Replace the power steering pump.
Stuck and improperly operated
power steering pump flow control
valve.Replace the power steering pump.
The slippage of the pump drive
belt.Tighten the pump drive belt.
Contaminated air in the power
steering system.Bleed the power steering system.
