2003 DAEWOO MATIZ Service Repair Manual

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.

FIVE-SPEED MANUAL TRANSAXLE 5B–33
DAEWOO M-150 BL2
D13B735A
13. Install the counter shaft bearing shim.

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

Select shim in order that clearance is within stan-
dard.
Unit : mm (in.)
Measured value (A) Shim thickness
0.33 − 0.37 (0.0130 – 0.0146) 0.45 (0.0177)
0.38 − 0.42 (0.0147 – 0.0165) 0.50 (0.0197)
0.43 − 0.47 (0.0169 – 0.0185) 0.55 (0.0217)
0.48 − 0.52 (0.0189 – 0.0205) 0.60 (0.0236)
0.53 − 0.57 (0.0209 – 0.0224) 0.65 (0.0256)
0.58 − 0.62 (0.0228 – 0.0244) 0.70 (0.0276)
0.63 − 0.67 (0.0248 – 0.0264) 0.75 (0.0295)
0.68 − 0.72 (0.0268 – 0.0283) 0.80 (0.0315)
0.73 − 0.77 (0.0287 – 0.0303) 0.85 (0.0335)
0.78 − 0.82 (0.0307 – 0.0323) 0.90 (0.0354)
0.83 − 0.87 (0.0327 – 0.0343) 0.95 (0.0374)
0.88 − 0.92 (0.0346 – 0.0362) 1.00 (0.0394)
0.93 − 0.97 (0.0366 – 0.0382) 1.05 (0.0413)
0.98 – 1.02 (0.0386 – 0.0402) 1.10 (0.0433)
1.03 – 1.07 (0.0406 – 0.0421) 1.15 (0.0453)
a. Straight ruler
b. Bearing outer race
c. Case surface
D13B736A
14. Install the side cover plate and the counter shaft fifth
gear.

Install the side cover plate (1).
Tighten
Tighten the screws to 6–7 N.m (53–62 lb–in).
Important: Use only new screws.

Install the counter shaft fifth gear (2).
Important: Position the machined boss side toward the
side cover plate.

5B–34 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B737A
15. Install the counter shaft fifth gear nut.

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 Nm (44–59 lb-ft).

Caulk the nut using a chisel and a hammer (2).
D103B710
16. Install the input shaft fifth gear bearing and the fifth
gear / synchronizer ring.

Insert the bearing into the input shaft.

Install the fifth gear, wave spring and synchroniz-
er ring matching synchronizer’s oil groove and in-
put shaft punched mark (1).
D103B738
17. Install the fifth gear synchronizer hub assembly.

Install the synchronizer springs to hub (1).

Install the synchronizer key (2).
Important: In case of assembling synchronizer sleeve
and hub, let A=B.

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

Position the chamfered spline of sleeve toward
inner side and install the hub to the sleeve (4).
D103B739
18. Install the fifth gear fork to the synchronizer hub as-
sembly.
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.

FIVE-SPEED MANUAL TRANSAXLE 5B–35
DAEWOO M-150 BL2
D103B740
20. Install the fifth gear shift fork pin.

Push the shift fork toward the fifth gear.

Install the shift fork pin using a pin punch and a
hammer(1).
Important: Use only new shift fork pin.
D103B741
21. Install the input shaft fifth gear snap ring, the fifth
gear shift fork snap ring and guide ball.

Install the fifth gear synchronizer plate.

Install the fifth gear snap ring (1).

Install the fork snap ring (2).
Important: Use only new snap ring.

Tighten the fork plug after inserting the guide ball
into the fork hole.
D13B742A
22. Install the side cover(1).

Coat the side cover with recommended sealant.
Side Cover Sealant THREE BOND 1215
Tighten
Tighten the side cover bolts to 8–12 Nm (71–106
lb-in).
D13B743A
23. Install the gear shift control case assembly.

Install the case gasket.

Install the gear shift control case.
Tighten

Tighten the bolts to 18–28 Nm (13–21 lb-ft) (a).

Tighten the shift interlock bolt to 18–28 Nm (13–
21 lb-ft) (b).

Install the select lever.
Tighten
Tighten the bolts to 18–28 Nm (13–21 lb-ft) (c).

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).

FIVE-SPEED MANUAL TRANSAXLE 5B–37
DAEWOO M-150 BL2
D103B747
3. Remove the input shaft fifth gear spacer, the left side
bearing and the fourth gear.

Position the fourth gear to the gear,bearing remov-
er DW09921–57810.

Remove the following parts.
a. Fifth gear spacer.
b. Left side bearing.
c. Fourth gear
D103B748
4. Remove the fourth gear bearing.
5. Remove the fourth gear synchronizer ring and wave
spring.
D103B749
6. Remove the third–fourth synchronizer circlip.
D103B750
7. Remove the third–fourth synchronizer hub assembly,
the third gear 1 synchronizer ring.

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

Remove the following parts.
a. Third–fourth synchronizer hub assembly.
b. Third gear and synchronizer ring.

5B–38 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B751
8. Disassemble the third–fourth synchronizer hub as-
sembly.

Remove the hub (1).

Remove the synchronizer sleeve and the key (2).

Remove the synchronizer springs (3).
D103B752
9. Remove the input shaft third gear bearing (1).
D103B753
Synchronizer Assembly Inspection
1. Inspecting wear of cone area.

After matching synchronizer ring to gear, measure
as shown in figure. Replace if it is below limit.
Unit : mm (in.)
Clearance Between Standard Limit Clearance Between
Gear and Ring
1.0 (0.039)0.5 (0.020)
D103B754
2. Inspecting cone contact condition.

When synchronizer mechanism is abnormal in op-
eration, connection between ring inner surface and
gear cone area is considered to be partially defec-
tive 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 in-
spection is difficult, check after applying red lead.
Cone area can be worn in wave form.

FIVE-SPEED MANUAL TRANSAXLE 5B–39
DAEWOO M-150 BL2
D103B755
3. Inspecting key slot width of synchronizer ring.

Measure key slot width of synchronizer ring. Re-
place if it exceeds limit.
Unit : mm (in.)
Key Slot Width Standard Limit
1st gear8.2 (0.323)8.6 (0.339)
2nd, 3rd, 4th gear9.6 (0.378)10.0 (0.394)
5th gear9.4 (0.370)9.8 (0.386)
D103B756
4. Inspecting wear of synchronizer ring.

Check for worn or damaged synchronizer ring
teeth. Replace it if necessary.
D103B757
5. Inspecting synchronizer key and spring.

Check for worn synchronizer key (1).

Check for weak, damaged or broken spring (2).
D103B758
Assembly Procedure
1. Install the third gear bearing, the third gear / synchro-
nizer ring.
a. Third gear / synchronizer ring.
b. Third gear bearing.
Important: Coat the inner parts; gear, bearing, oil seal
etc. with gear fluid.