2004 DAEWOO LACETTI Rod

FIVE–SPEED MANUAL TRANSAXLE 5B – 5
DAEWOO V–121 BL4
DIAGNOSIS
ISOLATE NOISE
Identify the cause of any noise before attempting to repair
the clutch, the transaxle, or their related link–ages.
Symptoms of trouble with the clutch or the manual trans-
axle include:
S A great effort required to shift gears.
S The sound of gears clashing and grinding.
S Gear blockout.
Any of these conditions requires a careful analysis. Make
the following checks before disassembling the clutch or
the transaxle for repairs.
Road Travel Noise
Many noises that appear to come from the transaxle may
actually originate with other sources such as the:
S Tires.
S Road surfaces.
S Wheel bearings.
S Engine.
S Exhaust system.
These noises may vary according to the:
S Size of the vehicle.
S Type of the vehicle.
S Amount of insulation used in the body of the ve-
hicle.
Transaxle Noise
Transaxle gears, like any mechanical device, are not ab-
solutely quiet and will make some noise during normal op-
eration.
To verify suspected transaxle noises:
1. Select a smooth, level asphalt road to reduce tire
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lu-
bricants thoroughly.
3. Record the speed and the gear range of the trans-
axle when the noise occurs.
4. Check for noises with the vehicle stopped, but with
the engine running.
5. Determine if the noise occurs while the vehicle op-
erates in:
S Drive – under a light acceleration or a heavy
pull.
S Float – maintaining a constant speed with a light
throttle on a level road.
S Coast – with the transaxle in gear and the
throttle partly or fully closed.
S All of the above.
Bearing Noise
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise
can be confused easily. Since side bearings are pre–
loaded, a differential side bearing noise should not dimin-
ish much when the differential/transaxle is run with the
wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound
that will continue when the vehicle is coasting and the
transaxle is in NEUTRAL. Since wheel bearings are not
pre–loaded, a wheel bearing noise should diminish con-
siderably when the wheels are off the ground.
Other Noise
Brinelling
A brinelled bearing causes a ”knock” or ”click” approxi-
mately every second revolution of the wheel because the
bearing rollers do not travel at the same speed as the
wheel. In operation, the effect is characterized by a low–
pitched noise.
A brinelled bearing is caused by excessive thrust which
pushes the balls up on the pathway and creates a triangu-
lar–shaped spot in the bearing race. A brinelled bearing
can also be caused from pressing one race into position
by applying pressure on the other race.
A false indication of a brinelled bearing occurs as a result
of vibration near the area where the bearing is mounted.
Brinelling is identified by slight indentations, resulting in a
washboard effect in the bearing race.
Lapping
Lapped bearing noise occurs when fine particles of abra-
sive materials such as scale, sand, or emery circulate
through the oil in the vehicle, causing the surfaces of the
roller and the race to wear away. Bearings that wear loose
but remain smooth, without spalling or pitting, are the re-
sult of dirty oil.
Locking
Large particles of foreign material wedged between the
roller and the race usually causes one of the races to turn,
creating noise from a locked bearing. Pre–loading regular
taper roller bearings to a value higher than that specified
also can result in locked bearings
Pitting
Pitting on the rolling surface comes from normal wear and
the introduction of foreign materials.
Spalling
Spalled bearings have flaked or pitted rollers or races
caused by an overload or an incorrect assembly that re-
sults in a misalignment, a cocking of bearings, or adjust-
ments that are too tight.
After completing these checks, refer to the ”Diagnosis
Chart” in this section.

5B – 6IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
SYMPTOM DIAGNOSIS
ChecksAction
Check for a knock at low speeds.S Replace any worn drive axle CV joints.
S Replace any worn side gear hub.
Check for a noise most pronounced on turns.S Correct any abnormalities in the differential gear.
Check for a clunk upon acceleration or deceleration.S Tighten any loose engine mounts.
S Replace any worn drive axle inboard joints.
S Replace any worn differential pinion shaft in the
case.
S Replace any worn side gear hub in the case.
Check for a clunking noise in turns.S Replace any worn outboard CV joint.
Check for a vibration.S Replace any rough wheel bearing.
S Replace any bent drive axle shaft.
S Replace any out–of–round tires.
S Balance any unbalanced tire.
S Replace any worn CV joint in the drive axle shaft.
S Correct an excessive drive axle angle by adjusting
the trim height.
Check for a noise in the NEUTRAL gear with the engine
running.S Replace any worn cluster bearing shaft.
S Replace any worn clutch–release bearing.
S Replace any worn input shaft cluster gears.
S Replace any worn first–gear/bearing.
S Replace any worn second–gear/bearing.
S Replace any worn third–gear/bearing.
S Replace any worn fourth–gear/bearing.
S Replace any worn fifth–gear/bearing.
S Replace any worn mainshaft bearings.
Check for a noise in the first gear (1) only.S Replace any chipped, scored, or worn first–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn first–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the second gear (2) only.S Replace any chipped, scored, or worn second–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn second–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the third gear (3) only.S Replace any chipped, scored, or worn third–gear
constant mesh gears.
S Replace any worn third–fourth gear synchronizer.
S Replace any worn third–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.

FIVE–SPEED MANUAL TRANSAXLE 5B – 7
DAEWOO V–121 BL4
Checks Action
Check for a noise in the fourth gear (4) only.S Replace any chipped, scored, or worn fourth gear or
output gear.
S Replace any worn third–fourth gear synchronizer.
S Replace any worn fourth–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the fifth gear (5) only.S Replace any chipped, scored, or worn fifth gear or
output gear.
S Repair any worn fifth–gear synchronizer.
S Replace any worn fifth–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the reverse (R) gear only.S Replace any chipped, scored, or worn reverse idler
gear, idler–gear bushing, input gear, or output gear.
S Replace any worn first–second gear synchronizer.
S Replace any worn output gear.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
Check for a noise in all gears.S Add sufficient lubricant.
S Replace any worn bearings.
S Replace any chipped, scored, or worn input–gear
shaft or output–gear shaft.
Check for the transaxle slipping out of gear.S Adjust or replace the linkage, as needed.
S Adjust, repair, or replace any binding shift linkage.
S Tighten or replace the input–gear bearing retainer, as
needed.
S Repair or replace any worn or bent shift fork.
Check for a leak in the area of the clutch.S Repair the transaxle casing.
S Replace any damaged release bearing guide.
Check for a leak at the center of the transaxle.S Repair the transaxle casing.
S Repair the shift mechanism.
S Replace the damaged backup lamp switch.
Check for a leak at the differential.S Adjust or replace the bearing retainers.
S Tighten or replace the differential cover.
S Adjust or replace the drive axle shaft seals.

5B – 8IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
Checks Action
Check for a hard shift.S Replace any damaged release–bearing guide.
S Adjust, repair, or replace the shift mechanism.
S Adjust, repair, or replace the clutch–release system.
S Replace any chipped, scored, or worn fifth–gear syn-
chronizer.
S Replace any chipped, scored, or worn first–second
gear synchronizer.
S Replace any worn third–fourth gear synchronizer.
S Adjust, repair, or replace the shift lever and the rods.
Check for a clashing of gears.S Replace any damaged release–bearing guide.
S Adjust, repair, or replace the clutch–release system.
S Replace the chipped, scored, or worn input shaft/
gear–cluster gears.
S Replace any worn fifth–gear synchronizer.
S Replace any worn fifth–gear/bearing.
S Replace any worn first–gear/bearing.
S Replace any worn first–second gear synchronizer.
S Replace any worn second–gear/bearing.
S Replace any worn third–gear/bearing.
S Replace any worn third–fourth synchronizer.
S Replace any worn fourth–gear/bearing.
S Replace any worn reverse–idler gear.

5B – 14IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
1. Gear Shift Control
2. Bolt
3. Gear Shift Tube Bellows
4. Clamp
5. Bolt
6. Gear Shift Control Mode
7. Gear Shift Guide Control
8. Pin
9. Clip
10. Bolt
11. 1st & 2nd Gear Shift Fork
12. 1st & 2nd Gear Shift Rod
13. Pin
14. 3rd & 4th Gear Shift Fork
15. 3rd & 4th Gear Shift Rod
16. Pin
17. 5th Speed Engaging Piece
18. Gear Shift Rod Pawl
19. Reverse Gear Shift Fork
20. Reverse Gear Shift Rod
21. Pin
22. Gear Shift Rod
23. Shift Finger24. Gear Shift Lever Cover
25. Gear Shift Inter Lever
26. Plate
27. Compression Spring
28. Bush
29. Retaining Ring
30. Gear Shift Cover Gasket
31. Bolt
32. Plug
33. Plug
34. Speedometer Driven Gear
35. Bolt
36. Differential Gear Cover Gasket
37. Differential Gear Cover
38. Screw
39. Backup Lamp Switch
40. O–ring
41. Pin
42. Pin
43. Sleeve
44. Bush

FIVE–SPEED MANUAL TRANSAXLE 5B – 15
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CHECKING FLUID LEVEL
1. With the vehicle on a level surface and the fluid in
the transaxle cold, remove the filler plug and check
the fluid level. The fluid should come to the bottom
edge of the plug hole.
2. If the level is low, add SAE 80 manual transaxle
fluid through the filler plug hole until the fluid begins
to run out.
3. Reinstall the filler plug and tighten it securely.
4. If the fluid is contaminated, drain the oil after re-
moving the differential gear cover.
SHIFT LINKAGE ADJUSTMENT
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
Important : All the gears must be easy to engage when
the vehicle is stationary, the engine is running, and the
clutch is disengaged.
3. Loosen the rod clamp bolt.

5B – 16IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
4. Remove the adjustment hole plug from the shift
lever cover.
5. Turn the gearshift rod and fully insert a 5 mm (0.2
inch) gauge pin into the adjustment hole.
6. Remove the boot from the console.
7. Pull the boot upward to expose the shift control le-
ver mechanism.
8. Position the gearshift lever close to left side of the
NEUTRAL position.
9. Insert a 5 mm (0.2 inch) gauge pin into the holes to
align the gearshift lever with the gearshift lever
housing.
10. Tighten the rod clamp bolt.
Tighten
Tighten the rod clamp bolt to 14 NSm (124 lb–in).
11. Remove .the 5 mm (0.2 inch) gauge pin from the
adjustment hole.
12. Install the adjustment hole plug.
13. Remove the 5 mm (0.2 inch) gauge pin from the
gearshift lever.
14. Install the boot to the console.
15. Connect the negative battery cable.

5B – 18IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
GEARSHIFT LEVER HOUSING
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the rod clamp. Refer to ”Shift Linkage Ad-
justment” in this section.
3. Remove the console.
4. Remove the gearshift lever housing bolts and the
gearshift lever housing.
Installation Procedure
1. Install the gearshift lever housing and the gearshift
lever housing bolts.
Tighten
Tighten the gearshift housing bolts to 7 NSm ( 62 lb–
in).
2. Adjust the shift linkage.
3. Install the console.
4. Connect the negative battery cable.
SPEEDOMETER DRIVEN GEAR
Removal Procedure
1. Disconnect the speedometer speed sensor electri-
cal connector.
2. Remove the speedometer housing retaining bolt.
3. Remove the speedometer–driven gear and the
speedometer housing.