2004 DAEWOO LACETTI transaxle

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.

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).

FIVE–SPEED MANUAL TRANSAXLE 5B – 55
DAEWOO V–121 BL4
8. Install the differential assembly into the transaxle
case.
9. Install the right–side bearing retainer and the right-
side bearing retainer bolts.
Tighten
Tighten the right–side bearing retainer bolts to 25
NSm (18 lb–ft).
10. Install the bearing–adjusting ring.
11. Tighten the bearing–adjusting ring using the remov-
er/ installer KM–520.
Tighten
Tighten the bearing adjusting ring until there is no end
play with the differential.
Adjust the preload on the differential bearings.
Used Bearings:
1 NSm (9 lb–in) required to rotate the differential one
revolution per second.
New Bearings:
2 NSm (18 lb–in) required to rotate the differential one
revolution per second.
Tighten or loosen the bearing ring adjuster to get the
required preload on the bearings.
12. Install the bearing–adjusting ring–retainer plate and
the bearing–adjusting ring–retainer plate bolt.
Tighten
Tighten the bearing–adjusting ring–retainer plate bolt
to 5 NSm (44 lb–in).

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.

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.

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.