2003 DAEWOO MATIZ Service Repair Manual

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).

FIVE-SPEED MANUAL TRANSAXLE 5B–25
DAEWOO M-150 BL2
D103B704
6. Remove the select lever.

Remove the bolt (1).

Remove the select lever (2).
D103B705
7. Remove the gear shift control case assembly.

Remove the bolts (1).

Remove the shift interlock bolt (2).
Important: Certainly remove the shift interlock bolt.
Otherwise, gear shift control case can not be removed.

Remove the gear shift control case assembly (3).

Remove the gasket (4).
D103B706
8. Remove the side cover.

Remove the bolts (1).

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

Remove the sealant on the side cover and the
transaxle case.
D103B707
9. Remove the fifth–gear shift fork guide ball, the snap
ring and the input shaft fifth–gear snap ring.

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

Remove the guide ball using a magnet.

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

Remove the fifth–gear snap ring (3).

Remove the fifth–gear synchronizer plate.

5B–26 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B708
10. Remove the fifth–gear shift fork pin.

Shift the shift fork to the fifth–gear.

Remove the fork pin using a pin punch and a
hammer (1).
D103B709
11. Remove the input shaft fifth–gear fork and synchro-
nizer hub assembly.

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

Remove the sleeve, key and spring from the syn-
chronizer hub assembly.
D103B710
12. Remove the input shaft fifth–gear, the synchronizer
ring and the fifth–gear bearing.

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

Remove the fifth–gear bearing.
D103B711
13. Remove the countershaft fifth–gear.

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).

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

FIVE-SPEED MANUAL TRANSAXLE 5B–27
DAEWOO M-150 BL2
D103B712

Remove the counter shaft fifth–gear (4).
D103B713
14. Remove the side cover plate and the counter shaft
bearing shim.

Remove the screws (1).

Remove the side cover plate (2).

Remove the counter shaft bearing shim.
D103B714
15. Remove the shift shaft spring and ball.

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

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

Remove the bolt and remove the first–second
gear shift shaft spring and ball (3).
Important: There is difference between the fifth–re-
verse gear shift shaft spring and the others. Mark it to
distinguish easily when installing.
D103B715
16. Remove the reverse idle gear shaft bolt.
Important: The case (Left) can not be removed without
removing the reverse idle gear shaft bolt.

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.

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).