2004 DAEWOO LACETTI Gear

FIVE–SPEED MANUAL TRANSAXLE 5B – 45
DAEWOO V–121 BL4
11. Install the thrust washer and the ring.
12. Install the second–gear needle bearing.
13. Install the second gear.
14. Install the first–second gear blocking ring.

5B – 46IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
15. Install the first–second synchronizer gear.
16. Install the washer and the snap ring.
17. Install the first–gear needle bearing.
18. Install the keys onto the first–second synchronizer
gear.

FIVE–SPEED MANUAL TRANSAXLE 5B – 47
DAEWOO V–121 BL4
19. Install the synchronizer hub sleeve containing the
synchronizer spring.
20. Install the outer blocking ring.
21. Install the mainshaft wear plate, the flat–type first-
gear needle bearing, and the first gear.
22. Install the snap ring.
23. Press on the mainshaft bearing.

FIVE–SPEED MANUAL TRANSAXLE 5B – 49
DAEWOO V–121 BL4
7. Remove the clutch–release bearing and the clutch–
release bearing guide. Refer to Section 5C, Clutch.
8. Remove the speedometer–driven gear bolt and the
speedometer–driven gear from the transaxle hous-
ing.
Assembly Procedure
1. Install the speedometer–driven gear bolt and the
speedometer–driven gear into the transaxle hous-
ing.
Tighten
Tighten the speedometer–driven gear bolt to 5 NSm
(44 lb–in)
2. Install the clutch–release bearing guide and the
clutch–release bearing. Refer to Section 5C,
Clutch.
3. Install the backup lamp switch into the transaxle
housing.
Tighten
Tighten the backup lamp switch to 20 NSm (15 lb–ft).
4. Install the differential into the transaxle housing.
Refer to ”Differential” in this section.
5. Install the bearing plate, with the shafts attached.
6. Install the bearing plate bolts.
Tighten
Tighten the bearing plate bolts to 22 NSm (16 lb–ft).

5B – 50IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
7. Install the transaxle cover and the transaxle cover
bolts.
Tighten
Tighten the transaxle cover bolts to 18 NSm (13 lb–ft).
8. Install the gearshift lever cover and the gearshift
lever cover bolts.
Tighten
Tighten the gearshift lever cover bolts to 22 NSm (16
lb–ft).
9. Install the transaxle into the vehicle. Refer to
”Transaxle Assembly” in this section.
DIFFERENTIAL
Tools Required
KM–520 Remover/Installer
KM–525 Installer
J–22888–20–A Bearing Puller with J–22888–35 Puller
Legs
KM–522 Installer
Disassembly Procedure
1. Remove the differential cover bolts, the differential
cover, and the differential cover gasket.
2. Remove the bearing–adjusting ring retainer plate
bolt and the bearing–adjusting ring retainer plate.

FIVE–SPEED MANUAL TRANSAXLE 5B – 51
DAEWOO V–121 BL4
3. Remove the bearing–adjusting ring using the re-
mover/ installer KM–520.
4. Remove the right–side bearing–retainer bolts and
the right–side bearing retainer.
5. Remove the differential assembly from the trans-
axle case.
6. Remove the ring gear bolts.

5B – 52IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
7. Separate the ring gear from the differential housing.
8. Drive the pinion gear shaft lock pin from the differ-
ential housing and the pinion gear shaft.
9. Remove the pinion gear shaft.
10. Remove the pinion gears and the washers.
11. Remove the side gears and the side thrust wash-
ers.

FIVE–SPEED MANUAL TRANSAXLE 5B – 53
DAEWOO V–121 BL4
12. Remove both of the differential bearings using the
bearing puller J–22888–20–A with the puller legs
J–22888–35.
13. Remove the speedometer drive gear from the dif-
ferential gear housing.
Assembly Procedure
1. Install the speedometer drive gear onto the differen-
tial gear housing using the installer KM–525.
2. Install both of the differential bearings using the in-
staller KM–522.