2004 DAEWOO LACETTI Gear

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.

FIVE–SPEED MANUAL TRANSAXLE 5B – 17
DAEWOO V–121 BL4
GEARSHIFT LEVER
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
Removal Procedure
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
3. Disconnect the boot from the console cover.
4. Lift the console cover upward to expose the shift
control lever mechanism.
5. Rotate the gearshift lever stop clamp and remove it.
6. Remove the gearshift lever from the gearshift lever
shaft.
Installation Procedure
1. Install the gearshift lever into the gearshift lever
shaft.
2. Install the gearshift lever stop clamp.
3. Rotate the gearshift lever stop clamp to secure it.
4. Lower the boot and connect it to the console cover.
5. 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.

FIVE–SPEED MANUAL TRANSAXLE 5B – 19
DAEWOO V–121 BL4
Installation Procedure
1. Coat the O–ring with petroleum jelly.
2. Install the speedometer–driven gear and the
speedometer housing.
3. Install the speedometer housing retaining bolt.
Tighten
Tighten the speedometer housing retaining bolt to 4
NSm (35 lb–in).
4. Connect the speedometer speed sensor electrical
connector.
SHIFT LINKAGE ASSEMBLY
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 clip and the bolt from universal joint.
4. Separate the universal joint from the transaxle.
5. Remove the fixing shaft pin and separate the link-
age connection part from the transaxle rear mount-
ing bracket.
6. Remove the shift linkage assembly.

5B – 26IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
UNIT REPAIR
MAJOR COMPONENT DISASSEMBLY
Tools Required
J–6125–B Slide Hammer
J–22888–20–A BearingPuller with J–22888–35 Puller
Legs
KM–553–A Fifth Gear Puller
J–36633 Snap Ring Retainer
KM–113–2 Base
J–42469 Shift Rod Remover
KM–552 Fixture
Disassembly Procedure
1. Remove the transaxle from the vehicle. Refer to
”Transaxle Assembly” in this section.
2. Remove the filler plug at the cover.
3. Remove the bolts from the gearshift lever cover.
4. Remove the gearshift lever cover.

FIVE–SPEED MANUAL TRANSAXLE 5B – 27
DAEWOO V–121 BL4
5. Bolt the gearshift lever cover to the fixture KM–552.
6. Position the fixture KM–552 into the base
KM–113–2.
7. Remove the snap ring, the bushing, the spring, and
the intermediate lever.
8. Remove the shift finger lever pin.
9. Remove the gearshift rod and the shift finger lever.

5B – 28IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
10. Remove the bolt and the speedometer–driven gear
from the transaxle housing.
11. Remove the transaxle cover bolts.
12. Remove the transaxle cover.
13. Shift the transaxle into second gear.
14. Remove the bearing plate bolts.