2003 DAEWOO MATIZ Service Repair Manual

5B–40 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B759
2. Assemble the third–fourth synchronizer hub assem-
bly.

Install the synchronizer springs to the hub.

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

Install the hub to the sleeve.
a. Sleeve.
b. Hub.
D103B760
3. Install the third–fourth synchronizer hub assembly.

Insert the hub assembly into the input shaft (1).
Important: Position the longer flange of hub toward the
third gear and match the key and the ring groove.

Install the hub assembly using a hammer and the
gear, bearing installer DW09940–53111.
D13B761A
Notice: When installing gear, bearing and hub assem-
bly, install them slowly using the gear, bearing installer
DW09940–53111 and a hammer. If overpressed, the
gear teeth may be damaged.
D103B749
4. Install the third–fourth synchronizer circlip.
5. Install the fourth synchronizer ring and wave spring.
Important: Match the ring groove to the key of hub.

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–42 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
Disassembly Procedure
1. Remove the gear unit. Refer to “Gear Unit” in this
section.
2. Remove the counter shaft right side bearing.
D103B766
3. Remove the counter shaft left side bearing and the
fourth gear.

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

Remove the following parts by pressing.
a. Counter shaft left side bearing.
b. Fourth gear.
D103B767
4. Remove the counter shaft third–fourth gear spacer.
5. Remove the counter shaft third gear and second gear.

Position the second gear to the gear, bearing re-
mover DW09921–57810.

Remove the following parts by pressing
a. Third gear.
b. Second gear.
D103B768
6. Remove the counter shaft second gear bearing.
7. Remove the second gear synchronizer ring.
8. Remove the first–second gear synchronizer circlip.

FIVE-SPEED MANUAL TRANSAXLE 5B–43
DAEWOO M-150 BL2
D103B769
9. Remove the counter shaft first–second gear syn-
chronizer hub assembly, the first gear / the first gear
synchronizer ring.

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

Remove the following parts by pressing.
a. Synchronizer hub assembly.
b. First gear / First gear synchronizer ring.

Remove the first gear synchronizer ring from the
first gear.
D103B770
10. Disassemble the first–second gear synchronizer
hub assembly.

Push the hub from the hub assembly (1).

Disassemble the synchronizer sleeve and key
(2).

Disassemble the synchronizer springs (3).
D103B771
11. Remove the counter shaft first gear bearing.
D103B772
Synchronizer Hub and Sleeve Inspection

Check the sleeve for improper operation after assem-
bling the hub and the sleeve.

Check the wear of hub and sleeve.

Replace synchronizer hub or sleeve if necessary.

5B–44 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B773
Assembly Procedure
1. Install the related counter shaft first gear.

Install the first gear bearing (1).

Install the first gear (2).

Install the first gear synchronizer ring (3)
Important: Coat the inner parts; gear, bearing and oil
seal etc. with gear fluid.
Important: Be careful there is the difference of key
groove width between the first synchronizer ring and the
second synchronizer ring.
D103B774A
Unit : mm (in.)




First synchronizer ring (A)
: 8.2 (0.323)


Key Groove Width
Second synchronizer ring
(B) : 9.6 (0.378)
D103B775
2. Assemble the first–second synchronizer hub assem-
bly.

Install the synchronizer springs to hub.

Install the synchronizer keys to hub.
Important: Let (A)=(B) when installing the keys.

Install the hub to the sleeve.
a. Sleeve.
b. Hub.
D103B776
3. Install the first–second synchronizer hub assembly.

Insert the hub assembly into the counter shaft us-
ing the gear, bearing installer DW09940–53111,
the gear bearing remover/installer KM466–A and a
hammer (1).
Important: Position the synchronizer key to the first
gear synchronizer ring groove.

FIVE-SPEED MANUAL TRANSAXLE 5B–45
DAEWOO M-150 BL2
D103B768
4. Install the second synchronizer ring.
Important: Position the second synchronizer ring groove
to the synchronizer hub key.
5. Install the first–second gear synchronizer circlip.
D103B777
6. Install the related counter shaft second gear.

Install the second gear bearing (1).

Install the second gear (2).
D103B778
7. Install the counter shaft third gear and the third–fourth
gear spacer.

Insert the third gear and the third–fourth gear
spacer into the counter shaft.

Install the following parts using the gear, bearing
installer DW09913–80112 and a hammer.
a. Third–fourth gear spacer.
b. Third gear.
D103B779
8. Install the counter shaft fourth gear.

Install the fourth gear to the counter shaft using the
gear, bearing installer DW09925–98221 and a
hammer (1).

5B–46 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B780
9. Install the counter shaft left side bearing.

Install the left side bearing to the counter shaft us-
ing the gear, bearing installer DW09925–98221
and a hammer (1).
D103B765
10. Install the counter shaft right side bearing.
11. Install the gear unit. Refer to “Gear Unit” in this sec-
tion.
D103B781
GEAR SHIFT FORK
Disassembly Procedure
1. Remove the gear unit. Refer to “Gear Unit” in this
section.
2. Remove the each shift shaft assembly from the gear
unit.
3. Remove the first–second gear shift shaft assembly.

Fix the shift shaft assembly to a vise with protector.

Remove the first–second gear fork pin using a pin
punch and a hammer (1).

Remove the first–second gear shift fork (2).
D103B783

Remove the first–second gear shift yoke pin using
a pin punch and a hammer (3).

Remove the first–second gear shift yoke (4).
Important: Mark the place and direction of shift fork and
yoke to install easily before removing them.

FIVE-SPEED MANUAL TRANSAXLE 5B–47
DAEWOO M-150 BL2
D103B782
4. Disassemble the third–fourth gear shift shaft assem-
bly.

Fix the third–fourth gear shift shaft assembly to a
vise with protector.

Remove the third–fourth gear fork pin using a pin
punch and a hammer (1).

Remove the third–fourth gear fork (2).

Remove the third–fourth gear shift yoke pin using a
pin punch and a hammer (3).

Remove the third–fourth gear shift yoke (4).
D103B784
5. Disassemble the fifth–reverse gear shift shaft assem-
bly.

Remove the shift shaft not installed with yoke by
pushing (1).

Remove the following parts from the reverse shift
arm.
a. Fifth–reverse gear ball.
b. Reverse shift guide ball and spring.

Fix the shift shaft assembly to a vise with protector.

Remove the reverse gear shift arm pin using a pin
punch and a hammer (2).

Remove the reverse gear shift arm (3).
D103B785

Remove the fifth gear shift yoke pin using a pin
punch and a hammer (4).

Remove the fifth gear shift yoke (5).
D103B786
Inspection Procedure – Shift Shaft
1. Check for bent, deformed or damaged shift shaft.
2. Replace shift shaft if necessary.