2004 DAEWOO LACETTI differential

5A2 – 210IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
5. Using a suitable puller, remove the tapered roller
bearing of transaxle case side.
6. Using a pin punch and hammer, drive out the pin
from the ring gear side.
7. Remove the differential pinion shaft from the case.
8. Remove the 2 differential pinion gears, 2 differential
side gears, 2 differential pinion thrust washers and
2 differential side gear thrust washers.

5A2 – 212IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Assembly Procedure
1. Using transaxle housing side bearing outer race
adapter DW240–140 and adapter handle
DW240–170, install a new side bearing outer race
into the transaxle housing.
2. Install the shim to the transaxle case.
Notice : First install a shim of the same thickness as be-
fore.
3. Install a new side bearing outer race into the trans-
axle case.
4. Coat the thrust washers, side gears, pinion gears
and pinion thrust washers with ATF.
5. Install the 2 differential side gear thrust washers to
2 differential side gears.
6. Install the 2 side gears with 2 thrust washers, 2 pin-
ion gears and 2 pinion thrust washers into the dif-
ferential case.
7. Coat the pinion shaft with ATF.

AISIN AUTOMATIC TRANSAXLE 5A2 – 213
DAEWOO V–121 BL4
8. Install the pinion shaft so as to align the lock pin
holes on the pinion shaft and differential case.
9. Measure the side gear backlash while holding 1
pinion gear toward the case.
S Standard backlash:
0.05
0.20 mm (0.0020–0.0079 in.)
If the backlash is out of specification, install the
correct thrust washer to the side gear.
10. Referring to the table below, select thrust washers
which will ensure that the backlash is within the
specification.
Try to select washers of the same size for both
sides.
Thrust washer thickness : mm (in.)
Thickness
Thickness
0.95 (0.0374)1.10 (0.0433)
1.00 (0.0394)1.15 (0.0453)
1.05 (0.0413)1.20 (0.0472)
If the backlash is not within the specification,
install a thrust washer of a different thickness.
11. Using a hammer and punch, drive in the pin
through the case and hole in the pinion shaft.

5A2 – 214IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
12. Using a hammer and chisel, stake the differential
case.
13. Using a press, install the tapered roller bearing into
the differential case.
14. Using a press, install the tapered roller bearing into
the differential case.
15. Remove any formed in place gasket (FIPG) materi-
al and be careful not to get oil on the contacting
surfaces of the transaxle housing or transaxle case.
16. Install the differential to the transaxle case.

AISIN AUTOMATIC TRANSAXLE 5A2 – 215
DAEWOO V–121 BL4
17. Install the transaxle housing and 16 bolts of the
transaxle housing temporarily.
18. Tighten 8 or 9 bolts out of 16 bolts of the transaxle
housing completely.
Tighten
Tighten the bolts to 29 NSm (22 lb–ft).
19. Using differential preload adapter DW240–130, turn
the differential gear assembly right and left 2 or 3
times to allow the bearing settle.
20. Using differential preload adapter DW240–130 and
small torque wrench, measure the preload of the
differential gear.
S Preload:
New bearing: 0.78–1.37 N.m (6.9–12.2 lb –in)
Used bearing : 0.39–0.69 N.m (3.5
6.1 lb–in)
If the preload is not within the specification, re-
move the differential from the transaxle case.
Re–select the transaxle case side adjusting
shim according to the following table.
S Adjusting shim thickness :mm (in.)
Mark
ThicknessMarkThickness
A1.80 (0.0709)N2.26 (0.0890)
B1.85 (0.0728)P2.29 (0.0902)
C1.90 (0.0748)Q2.32 (0.0913)
D1.95 (0.0768)R2.35 (0.0925)
E2.00 (0.0787)S2.40 (0.0945)
F2.05 (0.0807)T2.45 (0.0965)
G2.08 (0.0819)U2.50 (0.0984)
H2.11 (0.0831)V2.55 (0.1004)
J2.14 (0.0843)W2.60 (0.1024)
K2.17 (0.0854)X2.65 (0.1043)
L2.20 (0.0866)Y2.70 (0.01063)
M2.23 (0.0878)

5A2 – 216IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
21. Using a plastic hammer, remove the 16 bolts and
transaxle housing.
22. Remove the differential gear from the transaxle
case.
23. Clean the contact surface of the differential case.
24. Heat the ring gear in water and boil for 10 minutes.
25. Carefully remove the ring gear from the water.
26. After the moisture on the ring gear has completely
evaporated, quickly install the ring gear to the differ-
ential case.
27. Install the 8 bolts.
Tighten
Tighten the bolts to 102 NSm (75 lb–ft).

5A2 – 220IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Output Shaft Speed (ISS) Sensor
OSS sensor is located on the upper position of the trans-
axle and detects the vehicle speed from the rotation num-
ber of the differential gear.
Shift Control
When the ATF is below specification (15°C), 4th up–shift
is prevented.

5A2 – 226IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
6. Ring gear rotates clockwise.
7. Counter drive gear rotates clockwise for ring gear and one.
8. Counter drive gear rotates counterclockwise
9. Differential gear drive pinion rotates counterclockwise for counter driven gear and one.
10. Differential gear rotates clockwise.
( Engine Brake)
1. Counter drive gear and Planetary ring gear rotates counterclockwise.
2. Planetary long pinion rotates itself counterclockwise.
3. Planetary short pinion rotates itself clockwise.
4. Planetary carrier revolves clockwise due to rotation itself counterclockwise of planetary long pinion, but driving
force loses due to free of 1 way clutch NO.2 (F2). Therefore Engine brake does not operate.