2004 DAEWOO LACETTI Lamp

AISIN AUTOMATIC TRANSAXLE 5A2 – 139
DAEWOO V–121 BL4
9. Using transaxle housing oil seal installer
DW260–031–01 and a hammer, drive in a new
transaxle housing oil seal.
S Oil seal in depth: 3.1mm (0.122 in.)
10. Install a new outer tapered roller bearing race into
the transaxle housing.
Notice : Press
fit the outer tapered roller bearing race un-
til it contacts the transaxle housing.
11. Install the transaxle lube apply pipe and differential
gear lube apply pipe to the transaxle housing.
12. Install the No.1 transaxle apply pipe clamp to the
transaxle housing with the bolt.
Tighten
Tighten the bolt to 5.4 NSm (48 lb–in).
13. Install the oil reservoir lock plate to the transaxle
housing with the 3 bolts.
Tighten
Tighten the bolts to 5.4 NSm (48 lb–in).

5A2 – 162IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
114. Connect the manual valve control rod to the
manual valve lever as shown in the illustration.
115. Install the valve body assembly to the trans-
axle case.
Tighten
Tighten the bolts to 11 NSm (97 lb–in).
Notice : When installing the valve body to the transaxle
case, do not let each of accumulator pistons B1,C1,and
C2 incline. When installing the valve body to the transaxle
case, do not hold the solenoids.
116. Connect the transaxle wire connector and har-
ness to the valve body assembly.
117. Connect the 5 connectors.
a. Lock–up control solenoid
b. Pressure control solenoid.
c. No.2 shift solenoid.
d. No.1 shift solenoid.
e. Timing solenoid
118. Install the TFT sensor with clamp.
Notice : Make sure that the transaxle wire does not come
out from the oil pan installation surface.
119. Install a new gasket to the oil strainer.

5A2 – 218IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
TRANSAXLE DESCRIPTION
The new automatic transmission is an electronically con-
trolled 4–speed automatic transmission with Lock–up
mechanism.
The transmission is mainly composed of the torque con-
verter with lock up clutch, newly developed 4–speed plan-
etary gear unit, the hydraulic control system and the elec-
tric control system.
ELECTRONICAL COMPONENTS
Transmission Control Module (TCM)
The TCM primarily controls shift points and lockup en-
gagement. It is located on the driver side under the instru-
ment panel.
The transmission is controlled by an electronic shift sys-
tem. The Transmission Control Module (TCM) processes
input signals. From the information received, the TCM
controls the transmission hydraulic system.
The electronic shift system consists of the following :
S Transmission control module (TCM)
S Shift solenoids (SS1 and SS2)
S Pressure control solenoid (PCS)
S Lockup solenoid
S Input shaft speed (ISS) sensor
S Output shaft speed (OSS) sensor
S Transmission Fluid Temperature (TFT) sensor
S Transmission Range (TR) Switch
Transmission Range (TR) Switch
Transmission Range (TR) Switch transmits the informa-
tion which range includes shift lever of A/T to Starter and
TCM.
S It is possible for TR switch to start an engine in only
”P” and ”N”. (Prevention of reckless driving)
S TR switch makes backup lamp turn on when re-
versing.
S It is used for TR switch to shift control.
TR switch transmits the information by combination of
starter and reverse circuit to vehicle side directly without
TCM.
Shift Solenoid No 1,2 (SS1, SS2)
2 shift solenoids are installed directly in the valve body.
The solenoids operate of ON and OFF by the control sig-
nal from TCM. Combinations of 2 solenoids, SS1 and SS2
changes gear ranges.

5B – 2IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Backup Lamp Switch2015–
Bearing Plate Bolts2216–
Bearing Retainer Bolts, Right Side2518–
Bearing–Adjusting Ring–Retainer Plate Bolt5–44
Clutch–Release Cylinder Retaining Bolts2015–
Damping Block Connection Nut and Bolt6850–
Differential Cover Bolts4030–
Fifth–Gear Fork Bolts2216–
Fifth–Gearshift Connector Bolts7–62
Flywheel Inspection Cover Bolts7–62
Gearshift Housing Bolts7–62
Gearshift Lever Cover Bolts2216–
Input Driveshaft Detent Screw1511–
Rear Damping Block Retaining Bolts6850–
Rear Mounting Bracket Bolts9066–
Ring–Gear Bolts7052–
Rod Clamp Bolt14–124
Speedometer Housing Retaining Bolt4–35
Speedometer–Driven Gear Bolt5–44
Transaxle Cover Bolts1813–
Transaxle Lower Retaining Bolts(a)7354–
Transaxle Lower Retaining Bolt(b)3123–
Transaxle Lower Retaining Bolts(c)2115–
Transaxle Upper Retaining Bolts7354–
Transaxle Upper Mounting Bracket Bolts4835–

FIVE–SPEED MANUAL TRANSAXLE 5B – 7
DAEWOO V–121 BL4
Checks Action
Check for a noise in the fourth gear (4) only.S Replace any chipped, scored, or worn fourth gear or
output gear.
S Replace any worn third–fourth gear synchronizer.
S Replace any worn fourth–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the fifth gear (5) only.S Replace any chipped, scored, or worn fifth gear or
output gear.
S Repair any worn fifth–gear synchronizer.
S Replace any worn fifth–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the reverse (R) gear only.S Replace any chipped, scored, or worn reverse idler
gear, idler–gear bushing, input gear, or output gear.
S Replace any worn first–second gear synchronizer.
S Replace any worn output gear.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
Check for a noise in all gears.S Add sufficient lubricant.
S Replace any worn bearings.
S Replace any chipped, scored, or worn input–gear
shaft or output–gear shaft.
Check for the transaxle slipping out of gear.S Adjust or replace the linkage, as needed.
S Adjust, repair, or replace any binding shift linkage.
S Tighten or replace the input–gear bearing retainer, as
needed.
S Repair or replace any worn or bent shift fork.
Check for a leak in the area of the clutch.S Repair the transaxle casing.
S Replace any damaged release bearing guide.
Check for a leak at the center of the transaxle.S Repair the transaxle casing.
S Repair the shift mechanism.
S Replace the damaged backup lamp switch.
Check for a leak at the differential.S Adjust or replace the bearing retainers.
S Tighten or replace the differential cover.
S Adjust or replace the drive axle shaft seals.

5B – 14IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
1. Gear Shift Control
2. Bolt
3. Gear Shift Tube Bellows
4. Clamp
5. Bolt
6. Gear Shift Control Mode
7. Gear Shift Guide Control
8. Pin
9. Clip
10. Bolt
11. 1st & 2nd Gear Shift Fork
12. 1st & 2nd Gear Shift Rod
13. Pin
14. 3rd & 4th Gear Shift Fork
15. 3rd & 4th Gear Shift Rod
16. Pin
17. 5th Speed Engaging Piece
18. Gear Shift Rod Pawl
19. Reverse Gear Shift Fork
20. Reverse Gear Shift Rod
21. Pin
22. Gear Shift Rod
23. Shift Finger24. Gear Shift Lever Cover
25. Gear Shift Inter Lever
26. Plate
27. Compression Spring
28. Bush
29. Retaining Ring
30. Gear Shift Cover Gasket
31. Bolt
32. Plug
33. Plug
34. Speedometer Driven Gear
35. Bolt
36. Differential Gear Cover Gasket
37. Differential Gear Cover
38. Screw
39. Backup Lamp Switch
40. O–ring
41. Pin
42. Pin
43. Sleeve
44. Bush

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.