2004 DAEWOO LACETTI aisin automatic transaxle

AISIN AUTOMATIC TRANSAXLE 5A2 – 157
DAEWOO V–121 BL4
91. Apply formed in place gasket (FIPG) to the trans-
axle rear cover.
FIPG: three bond 1281 or equivalent
Seal bend width: 1.2 mm (0.047 in.)
92. Install the transaxle rear cover to the transaxle case
with the 9 bolts.
Tighten
Tighten the bolts to 25 NSm (18 lb–ft).
93. Install the counter driven gear assembly to the
transaxle case.
94. Install the differential gear assembly to the trans-
axle case.

5A2 – 158IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
95. Install the direct clutch hub to the transaxle case.
96. Install the thrust bearing race and thrust needle roll-
er bearing to the transaxle case.
S Race and bearing: mm (in.)
Inner diameterOuter diameter
Race20.5 (0.807)32.6 (1.283)
Bearing17.8 (0.701)30.2 (1.189)
97. Install the direct clutch assembly to the transaxle
case.
98. Install new apply gasket.

AISIN AUTOMATIC TRANSAXLE 5A2 – 159
DAEWOO V–121 BL4
99. Install the thrust needle roller bearing to the trans-
axle case.
Notice : Check the direction of the bearing.
100. Place the oil pump through the input shaft, and
align the bolt holes of the oil pump with the trans-
axle case.
101. Install the 6 oil pump bolts.
Tighten
Tighten the bolts to 25 NSm (18 lb–ft).
102. Measure the end play in axial direction.
Notice : If the end play is not as specified, select and re-
place the thrust needle roller bearing.
S End play 0.3
0.9 mm (0.012
0.035 in.)
S Bearing: mm (in.)
Inner diameter
Outer
diameterThichness
32.5 (1.280)48.5 (1.909)4.21 (0.1657)
32.9 (1.295)48.5 (1.909)3.62 (0.1425)
103. Make sure that the input shaft rotates smooth-
ly.

5A2 – 160IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
104. Remove any packing material and be careful
not to get oil on the contacting surfaces of the
transaxle housing or transaxle case.
105. Apply FIPG (formed in place gasket) to the
transaxle housing.
FIPG: Three bond 1281 or equivalent.
Seal bend width: 1.2 mm (0.047 in.)
106. Install the transaxle housing to the transaxle
case with the 16 bolts.
Tighten
Tighten the bolts to 29 NSm (22 lb–ft).
S Apply seal packing or equivalent to the 3 bolts
indicated by arrows.
107. Coat a new O–ring with ATF, install it to the
transaxle wire.
108. Install the transaxle wire the to the transaxle
case with the bolt.
Tighten
Tighten the bolts to 5.4 NSm (48 lb–in).

AISIN AUTOMATIC TRANSAXLE 5A2 – 161
DAEWOO V–121 BL4
109. Coat new 6 O–rings with ATF and install them
to the pistons.
110. Coat the 3 springs and 3 accumulator pistons
with ATF, install them to the holes.
S Accumulator spring:
Spring
Free length
Outer
diameter
mm(in.)Color
B1(O/D & 2nd
brake)47.13(1.8555)/
16.0(0.630)Pink
C1(Forward
clutch)57.90(2.2795)/
17.2(0.677)–
C2(Direct
clutch)57.20(2.2520)/
17.5(0.689)Green
111. Coat a new apply gasket with ATF, install it to
the transaxle case.
112. Coat a new brake drum gasket with ATF, install
it to the transaxle case.
113. Install the spring and check valve.

5A2 – 162IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
114. Connect the manual valve control rod to the
manual valve lever as shown in the illustration.
115. Install the valve body assembly to the trans-
axle case.
Tighten
Tighten the bolts to 11 NSm (97 lb–in).
Notice : When installing the valve body to the transaxle
case, do not let each of accumulator pistons B1,C1,and
C2 incline. When installing the valve body to the transaxle
case, do not hold the solenoids.
116. Connect the transaxle wire connector and har-
ness to the valve body assembly.
117. Connect the 5 connectors.
a. Lock–up control solenoid
b. Pressure control solenoid.
c. No.2 shift solenoid.
d. No.1 shift solenoid.
e. Timing solenoid
118. Install the TFT sensor with clamp.
Notice : Make sure that the transaxle wire does not come
out from the oil pan installation surface.
119. Install a new gasket to the oil strainer.

AISIN AUTOMATIC TRANSAXLE 5A2 – 163
DAEWOO V–121 BL4
120. Install the oil strainer to the valve body with the
3 bolts.
Tighten
Tighten the bolts to 9.8 NSm (87 lb–in).
121. Install the 2 magnets in the oil pan.
122. Install a new gasket to the oil pan and install
them to the transaxle case with the 18 bolts.
Tighten
Tighten the bolts to 7 NSm (62 lb–in).
123. Install the output shaft speed (OSS) sensor.
Tighten
Tighten the bolt to 7.4 NSm (65 lb–in).

5A2 – 164IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
124. Install the No.1 breather plug.
125. Install the input shaft speed (ISS) sensor with
the bolt.
Tighten
Tighten the bolts to 5.4 NSm (48 lb–in).
126. Coat a new O–ring with ATF, install it to the
screw plug.
127. Install the screw plug to the transaxle case.
Tighten
Tighten the bolts to 7.4 NSm (65 lb–in).
128. Coat new 2 O–rings with ATF, install them to
the unions.
129. Install the 2 unions to the transaxle case.
Tighten
Tighten the unions to 25 NSm (18 lb–ft).
130. Install the TR switch onto the manual valve
lever shaft and temporarily install the 2 adjusting
bolts.
131. Install a new lock washer and nuts.
Tighten
Tighten the nuts to 12 NSm (106 lb–in).