2004 DAEWOO LACETTI aisin automatic transaxle

AISIN AUTOMATIC TRANSAXLE 5A2 – 149
DAEWOO V–121 BL4
54. Using a small torque wrench, while turning to count-
er drive gear 100 turn per minute and measure the
preload.
Notice : When the preload is smaller than the specifica-
tion, tighten the nut more and adjust the preload. Preload:
0.05–0.35 NSm (0.43–3.12 lb–in)
Tighten
Tighten the nut to 29 NSm (22 lb–ft) or less.
55. Stake the nut.
56. Install the planetary gear to the transaxle case.
57. Coat the planetary carrier thrust washer with petro-
leum jelly and install it onto the planetary gear.
58. Install the No.2 one–way clutch to the transaxle
case.

5A2 – 150IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
59. Check that the planetary gear turns freely counter-
clockwise and locks clockwise.
60. Install the anti–rattle clip in the place shown in the
illustration (the space between the No.2 one–way
clutch outer race and transaxle case), push the
anti–rattle clip in until you hear the ”click”.
61. Using vernier calipers, measure the free length of
the 2nd brake piston return spring together with
spring seat.
S Standard free length: 15.85 mm (0.6240 in.).
62. Check to see if the sliding surface of the disc, plate
and flange of 2nd brake are worn or burnt. If neces-
sary, replace them.
Notice : If the lining of the disc is peeling off or discolored,
or even if a part of the groove is defaced, replace all discs.
Notice : Before assembling new discs, soak them in ATF
for at least 15 minutes.

AISIN AUTOMATIC TRANSAXLE 5A2 – 151
DAEWOO V–121 BL4
63. Install the flange, 2 discs and 2 plates.
S Install in order : F
D
P
D
P
(D = Disc, P = Plate, F = Flange)
64. Install the 2nd brake return spring.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
65. Coat 2 new O–rings with ATF, install them to the
2nd brake piston.
66. Install the 2nd brake piston into the 2nd brake
clutch cylinder.
Notice : Be careful not to damage the O–rings.
67. Install the 2nd brake clutch cylinder to the transaxle
case.

5A2 – 152IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
68. Using brake spring compressor bolt / nut
DW240–060–01 and 2nd brake adapter
DW240–080, compress the 2nd brake piston return
spring.
69. Using a screwdriver, install the snap ring.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
70. Coat the thrust bearing race with petroleum jelly
and install it onto the front planetary sun gear.
S Race:
Inner diameter: 19.3 mm (0.760 in.)
Outer diameter : 29.0 mm (1.142 in.)
71. Install the front planetary sun gear to the transaxle
case.
72. Install the thrust washer and one–way clutch as-
sembly to the rear planetary sun gear.

AISIN AUTOMATIC TRANSAXLE 5A2 – 153
DAEWOO V–121 BL4
73. Coat the thrust bearing race with petroleum jelly
and install it onto the rear planetary sun gear and
one–way clutch assembly.
S Bearig:
Inner diameter: 42.5 mm (1.673 in.)
Outer diameter: 57.5 mm (2.264 in.)
Notice : Check the direction of the bearing.
74. Install the rear planetary sun gear and one–way
clutch assembly to the transaxle case.
75. Coat the thrust bearing race with petroleum jelly
and install it onto the transaxle case.
S Race:
Inner diameter: 34.95 mm (1.3760 in.)
Outer diameter: 45.50 mm (1.7913 in.)
Notice : Check the direction of race.
76. Coat the thrust needle roller bearing with petroleum
jelly and install it onto the forward clutch hub.
S Bearig:
Inner diameter: 33.3 mm (1.311 in.)
Outer diameter: 46.5 mm (1.831 in.)
Notice : Check the direction of bearing.

5A2 – 154IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
77. Install the forward clutch hub to the transaxle case.
78. Coat the thrust bearing race with petroleum jelly
and install it onto the forward clutch hub.
S Race:
Inner diameter: 19.3 mm (1.760 in.)
Outer diameter: 30.6 mm (1.205 in.)
79. Install the thrust bearing race and thrust needle roll-
er bearing to the forward & reverse clutch assem-
bly.
S Race and bearing diameter: mm(in.)
Inner diameterOuter diameter
Race18.1 (0.713)28.2 (1.110)
Bearing18.1 (0.713)29.6 (1.165)
80. Install the forward & reverse clutch assembly to the
transaxle case.

AISIN AUTOMATIC TRANSAXLE 5A2 – 155
DAEWOO V–121 BL4
81. Check to see if the sliding surface of the disc, plate
and flange of 2nd coast & O/D brake are worn or
burnt. If necessary, replace them.
Notice : If the lining of the disc is peeling off or discolored,
or even if a part of the printed mark is defaced, replace all
discs.
Notice : Before assembly new discs, soak them in ATF for
at least 15 minutes.
82. Using a screwdriver, install the snap ring to the
transaxle case.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
83. Install the flange, 2 discs and 2 plates to the trans-
axle case.
S Install in order: P
D
P
D
F
(P = Plate, D = Disc, F = Flange)
84. Clean the connected part the transaxle case and
transaxle rear cover.
85. As shown in the illustration, place a straight edge
on the transaxle case and measure the distance
between the 2nd coast & O/D brake flange and
straight edge using vernier calipers. (Dimension A).

5A2 – 156IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
86. As shown in the illustration, place a straight edge
on the O/D brake piston and measure the distance
between the transaxle rear cover and straight edge
using vernier calipers. (Dimension B).
87. Calculate the piston stroke value using the following
formula. Select a flange which satisfies the piston
stroke value and install it.
Piston stroke = Dimension A
Dimension B
Piston stroke : 0.65
1.05 mm (0.0256
0.0413
in.)
S Flange thickness : mm (in.)
Piston stroke
value
ThicknessMark
0.738 ~ 0.949
(0.02905 ~
0.03736)3.0
(0.118)0
0.950 ~ 1.149
(0.03740 ~
0.04524)3.2
(0.126)1
1.150 ~ 1.349
(0.04528 ~
0.05311)3.4
(0.134)2
1.350 ~ 1.549
(0.05315 ~
0.06098)3.6
(0.142)3
1.550 ~ 1.702
(0.06102 ~
0.06701)3.8
(0.150)0
88. Install new 4 apply gaskets to the transaxle rear
cover.
89. Coat the thrust neddle roller bearing with petroleum
jelly and install it onto the forward & reverse clutch
assembly.
S Bearig:
Inner diameter: 43.2 mm (1.701 in.)
Outer diameter: 62.0 mm (2.441 in.)
90. Remove any packing material and be careful not to
get oil on the contacting surfaces of the transaxle
rear cover or transaxle case.