2004 DAEWOO LACETTI Rod

FIVE–SPEED MANUAL TRANSAXLE 5B – 57
DAEWOO V–121 BL4
8. Install the third–fourth gearshift rod/fork holding pin.
9. Install the support bracket onto the bearing plate.
10. Install the first–second gearshift rod/fork onto the
bearing plate.
11. Install the first–second gearshift fork holding pin.

5B – 58IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
12. Install the support bracket bolts.
Tighten
Tighten the support bracket bolts to 7 NSm (62 lb–in).
13. Install the reverse gearshift rod/fork onto the bear-
ing plate.
14. Install the reverse gearshift rod/fork holding pin.
15. Install the rod lock pin and spring into the small plug
hole.

FIVE–SPEED MANUAL TRANSAXLE 5B – 59
DAEWOO V–121 BL4
16. Install the fourth–gearshift rod plugs.
17. Install the bolts and the fifth–gearshift connector
onto the bearing plate, using the pawl.
Tighten
Tighten the fifth–gearshift connector bolts to 7 NSm
(62 lb–in).
18. Install the input drive fifth gear using the installer
KM–554 and the installer sleeve KM–334.
19. Install the snap rings securing the fifth–drive gear.

5B – 62IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
31. Bolt the gearshift lever cover to the fixture KM–552.
32. Position the fixture into the base KM–113–2.
33. Install the gearshift rod, the shift finger lever, and
the gearshift lever pin.
34. Install the snap ring, the bushing, the spring, and
the intermediate lever.
35. Remove the gearshift lever cover from the base
KM–113–2 and the fixture KM–552.
36. Shift the transaxle into NEUTRAL.
37. Install the gearshift lever cover and the gearshift
lever cover bolts.
Tighten
Tighten the gearshift lever cover bolts to 22 NSm (16
lb–ft).
38. Install the transaxle cover and the transaxle cover
bolts.
Tighten
Tighten the transaxle cover bolts to 18 NSm (13 lb–ft).
39. Install the transaxle into the vehicle. Refer to
”Transaxle Assembly” in this section.

5C – 6ICLUTCH
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CLUTCH PEDAL
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the return spring from the clutch pedal.
3. Remove the clip and the pedal mounting shaft.
4. Remove the locking clip and push rod fixing pin.
5. Remove the push rod from the clutch pedal.
6. Remove the clutch pedal.
Installation Procedure
1. Install the clutch pedal.
2. Coat the push rod with multi–purpose grease.
3. Install the push rod to the clutch pedal.
4. Install the locking clip and push rod fixing pin.

CLUTCH 5C – 7
DAEWOO V–121 BL4
5. Coat the pedal mounting shaft with multi–purpose
grease.
6. Install the clip and the pedal mounting shaft.
7. Connect the return spring to the clutch pedal.
8. Adjust the clutch pedal play. Refer to ”Clutch Pedal
Adjustment” in this section.
9. Connect the negative battery cable.
CLUTCH PEDAL ADJUSTMENT
Adjustment Procedure
1. Determine the clutch pedal play. Depress the clutch
pedal lightly with your hand and measure the dis-
tance when you feel resistance.
2. Adjust the clutch pedal play. Loosen the locknut
and turn the pushrod. Clutch pedal play should
measure 6 to 12 mm (0.2 to 0.5 inch). Tighten the
locknut after adjustment.
3. Measure the clutch pedal travel. Press the clutch
pedal all the way to the floor. Measure from the
starting position to the ending position.
4. Adjust the clutch pedal travel. Loosen the locknut
and turn the bolt. Clutch pedal travel should mea-
sure 130 to 140 mm (5.1 to 5.5 inches). Tighten the
locknut after adjustment.

5C – 10ICLUTCH
DAEWOO V–121 BL4
Installation Procedure
1. Coat the spline on the clutch disc with multi–pur-
pose grease.
2. Align the pressure plate and the clutch disc onto
the flywheel using the clutch arbor J–42474.
3. Install the pressure plate bolts.
Tighten
Tighten the bolts to 15 NSm (11 lb–ft).
4. Remove the clutch arbor J–42474.
5. Install the transaxle into the vehicle. Refer to Sec-
tion 5B, Five–Speed Manual Transaxle.
6. Connect the negative battery cable.
CLUTCH MASTER CYLINDER
ASSEMBLY
Removal Procedure
Before disconnecting the reservoir tank hose, remove the
clutch/brake fluid from the reservoir tank.
1. Remove the locking clip.
2. Remove the push rod fixing pin and push rod.
3. Disconnect the hose clamp on the master cylinder.
4. Disconnect the master cylinder hose.
5. Remove the master cylinder pipe.

5C – 12ICLUTCH
DAEWOO V–121 BL4
5. Install the push rod fixing pin and push rod.
6. Install the locking clip.
7. Bleed the air. Refer to ”Air Bleeding” in this section.
8. Adjust the clutch pedal. Refer to ”Clutch Pedal Ad-
justment” in this section.
9. Fill the reservoir with clutch/brake fluid up to the
proper level.
CONCENTRIC SLAVE CYLINDER
Removal Procedure
1. Remove the transaxle from the vehicle. Refer to
Section 5B, Five–Speed Manual Transaxle.
2. Remove the concentric slave cylinder retaining
bolts.
3. Disconnect the concentric slave cylinder pipe from
the concentric slave cylinder.
Notice : When removing the bushing, Make sure not to re-
move it with excessive force.
4. Remove the bushing from the concentric slave cyl-
inder pipe in the transaxle housing.
5. Remove the concentric slave cylinder pipe.
Notice : For removal or installation, Make sure not to sep-
arate oil seal fixing spring from the back side of the con-
centric slave cylinder.
6. Remove the O–ring and the concentric slave cylin-
der.