Page 1878 of 2643
5B – 54IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
3. Install the side gears and the side thrust washers
into the differential housing.
4. Install the differential pinion gears and the differen-
tial pinion gear washers into the differential housing.
5. Install the pinion gear shaft into the differential
housing.
6. Install the pinion gear shaft lock pin into the differ-
ential housing and the pinion gear shaft.
7. Install the ring gear and the ring–gear bolts.
Tighten
Tighten the ring–gear bolts to 70 NSm (52 lb–ft).
Page 1880 of 2643
5B – 56IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
13. Install the differential cover gasket, the differential
cover, and the differential cover bolts.
Tighten
Tighten the differential cover bolts to 40 NSm (30 lb–
ft).
MAJOR COMPONENT ASSEMBLY
Tools Required
J–36633 Snap Ring Retainer
KM–334 Installer Sleeve
KM–552 Fixture
KM–554 Installer
KM–113–2 Base
Assembly Procedure
1. Join the mainshaft and the input shaft.
2. Compress the snap ring at the base of the main-
shaft and hold with the snap ring retainer J–36633.
3. Hold the snap ring at the base of the input drive-
shaft with the snap ring pliers.
4. Install the mainshaft/input shaft assembly onto the
bearing plate.
5. Release the mainshaft snap ring and the input shaft
snap ring.
6. Position the first–second gearshift fork.
7. Install the fifth gearshift lever into the bearing plate.
Page 1881 of 2643
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.
Page 1882 of 2643
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.
Page 1883 of 2643
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.
Page 1884 of 2643
5B – 60IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
20. Install the thrust washers, the retaining ring, and
the needle bearing into the mainshaft–driven fifth–
gear assembly.
21. Install the brass synchronizer ring onto the main-
shaft– driven fifth–gear assembly.
22. Install the mainshaft–driven fifth–gear assembly.
23. Install the fifth–drive gear synchronizer gear and
the synchronizer sleeve using installer KM–554.
24. Install the snap ring holding the fifth speed–driven
assembly.
Page 1885 of 2643
FIVE–SPEED MANUAL TRANSAXLE 5B – 61
DAEWOO V–121 BL4
25. Install the bolts and the fifth–gear fork onto the
bearing plate.
Tighten
Tighten the fifth–gear fork bolts to 22 NSm (16 lb–ft).
26. Remove the bearing plate from the fixture KM–552.
27. Shift the transaxle into second gear.
28. Install the bearing plate, with the shafts attached,
into the case.
29. Install the bearing plate bolts.
Tighten
Tighten the bearing plate bolts to 22 NSm (16 lb–ft).
30. Install the speedometer–driven gear and the
speedometer–housing retaining bolt into the trans-
axle housing.
Tighten
Tighten the speedometer housing retaining bolt to 4
NSm (35 lb–in).
Page 1886 of 2643
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.