2004 DAEWOO LACETTI aisin automatic transaxle

AISIN AUTOMATIC TRANSAXLE 5A2 – 117
DAEWOO V–121 BL4
UNIT REPAIR
MAJOR COMPONENT DISASSEMBLY
Tools Required
DW240–020 Brake/Clutch Spring Compressor
DW240–050 Overdrive Brake Adapter
DW240–060–01 Brake Spring Compressor Bolt/Nut
DW240–070 1st & Reverse Brake Adapter
DW240–080 2nd Brake Adapter
DW240–090 Planetary Ring Gear Remover
DW240–150 Transaxle Case Side Bearing Outer Race
Adapter
DW240–170 Adapter Handle
DW260–021–02 Automatic Transaxle Overhaul Fixture
(81–40 LE)
DW260–041 Planetary Ring Gear Nut Removal/Installa-
tion Socket
Disassembly Procedure
1. Remove the transaxle assembly from the vehicle.
Refer to”Transaxle Assembly” in this section.
2. Install the transaxle assembly to the transaxle sup-
port stand using Automatic Transaxle Overhaul Fix-
ture DW260–021–02 (81–40 LE).
3. Remove the nut, washer and control lever.
4. Using a screwdriver, unstake the lock washer.
5. Remove the two bolts and nut and pull out the
transmission range (TR) switch.
6. Remove the two unions the transaxle case.
7. Remove the two O–rings from the unions.

5A2 – 118IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
8. Remove the screw plug from the transaxle case.
9. Remove the O–ring from the screw plug.
10. Remove the bolt and the input shaft speed (ISS)
sensor.
11. Remove the breather plug.
12. Remove the O–ring from the breather plug.
13. Remove the bolt and the output shaft speed (OSS)
sensor.
14. Remove the 18 bolts.
15. Remove the oil pan and gasket.
16. Remove the drain plug from the oil pan.

AISIN AUTOMATIC TRANSAXLE 5A2 – 119
DAEWOO V–121 BL4
17. Remove the three bolts and oil strainer.
18. Remove the gasket from the oil strainer.
19. Remove the bolt and transmission fluid temperature
sensor with the clamp.
20. Disconnect the 5 solenoid connectors.
a. Lock–up control solenoid
b. Pressure control solenoid.
c. No.2 shift solenoid.
d. No.1 shift solenoid.
e. Timing solenoid
21. Support the valve body assembly and remove the
14 bolts.

5A2 – 120IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
22. Disconnect the manual valve control rod from the
manual valve lever, then remove the valve body
assembly.
23. Remove the check valve and spring.
24. Remove the brake drum gasket.
25. Remove the apply gasket.

AISIN AUTOMATIC TRANSAXLE 5A2 – 121
DAEWOO V–121 BL4
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
Notice : Blowing off the air may cause the piston’s jump–
out. When removing the piston, hold it with your hand us-
ing a waste cloth.
Notice : Take care not to splash automatic transaxle fluid
(ATF) when air–blowing.
26. Apply 392 kPa (57 psi) of compressed air to the oil
hole and remove the direct clutch (C2) accumulator
piston and spring.
27. Remove the spring.
28. Remove the 2 O–rings from the direct clutch (C2)
accumulator piston.
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
Notice : Blowing off the air may cause the piston’s jump–
out.When removing the piston, hold it with your hand using
a waste cloth.
Notice : Take care not to splash ATF when air–blowing.
29. Apply 392 kPa (57 psi) of compressed air to the oil
hole and remove the forward clutch (C1) accumula-
tor piston and spring.
30. Remove the spring.
31. Remove the 2 O–rings from the forward clutch (C1)
accumulator piston.

5A2 – 122IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
WARNING : USE CAUTION WHEN REMOVING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
Notice : Blowing off the air may cause the piston’s jump–
out.When removing the piston, hold it with your hand using
a waste cloth.
Notice : Take care not to splash ATF when air–blowing.
32. Apply 392 kPa (57 psi) of compressed air to the oil
hole and remove the O/D & 2nd brake (B1) clutch
accumulator piston and spring.
33. Remove the 2 O–rings from the O/D & 2nd brake
(B1) accumulator piston.
34. Remove the bolt and the transaxle wire from the
transaxle case.
35. Remove the O–ring from the transaxle wire.

AISIN AUTOMATIC TRANSAXLE 5A2 – 123
DAEWOO V–121 BL4
36. Remove the 16 bolts and tap on the circumference
of the transaxle housing with a plastic hammer to
remove the transaxle housing from the transaxle
case.
Important : Be careful not to drop the differential gear as-
sembly when the transaxle housing is removed.
37. Using a dial indicator, measure the input shaft end
play.
S End play : 0.3
0.9 mm (0.012–0.035 in.)
38. Remove the 6 bolts and oil pump.
39. Remove the differential gear assembly from the
transaxle case.

5A2 – 124IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
40. Remove the apply gasket.
41. Remove the direct clutch (C2) assembly from the
transaxle case.
42. Remove the thrust needle roller bearing from the
direct clutch assembly.
43. Remove the direct clutch (C2) hub, thrust needle
roller bearing and thrust bearing race from the
transaxle case.