2004 DAEWOO NUBIRA Manual Transaxle

FIVE–SPEED MANUAL TRANSAXLE 5B – 25
DAEWOO V–121 BL4
11. Connect the clutch release cylinder pipe.
12. Connect the speedometer speed sensor electrical
connector.
13. Connect the backup lamp switch electrical connec-
tor.
14. Remove the engine support fixture J–28467–B.
15. Install the drive axle shaft. Refer to Section 3B,
Manual Transaxle Drive Axle.
16. Install the shift linkage assembly. Refer to ”Shift
Linkage Assembly” in this section.
17. Install the battery and battery tray. Refer to Section
1E, ENGINE ELETRICAL.
18. Inspect the fluid level. Refer to ”Checking Fluid Lev-
el” in this section.

5B – 26IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
UNIT REPAIR
MAJOR COMPONENT DISASSEMBLY
Tools Required
J–6125–B Slide Hammer
J–22888–20–A BearingPuller with J–22888–35 Puller
Legs
KM–553–A Fifth Gear Puller
J–36633 Snap Ring Retainer
KM–113–2 Base
J–42469 Shift Rod Remover
KM–552 Fixture
Disassembly Procedure
1. Remove the transaxle from the vehicle. Refer to
”Transaxle Assembly” in this section.
2. Remove the filler plug at the cover.
3. Remove the bolts from the gearshift lever cover.
4. Remove the gearshift lever cover.

FIVE–SPEED MANUAL TRANSAXLE 5B – 27
DAEWOO V–121 BL4
5. Bolt the gearshift lever cover to the fixture KM–552.
6. Position the fixture KM–552 into the base
KM–113–2.
7. Remove the snap ring, the bushing, the spring, and
the intermediate lever.
8. Remove the shift finger lever pin.
9. Remove the gearshift rod and the shift finger lever.

5B – 28IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
10. Remove the bolt and the speedometer–driven gear
from the transaxle housing.
11. Remove the transaxle cover bolts.
12. Remove the transaxle cover.
13. Shift the transaxle into second gear.
14. Remove the bearing plate bolts.

FIVE–SPEED MANUAL TRANSAXLE 5B – 29
DAEWOO V–121 BL4
15. Remove the bearing plate from the case with the
shafts attached.
16. Shift the transaxle into reverse (R).
17. Bolt the bearing plate to the fixture KM–552 and
install the fixture KM–552 into the base KM–113–2.
18. Remove the bolts and the fifth–gear fork from the
bearing plate.
19. Remove the mainshaft–driven fifth–speed assembly
snap ring.

5B – 30IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
20. Remove the fifth driven gear synchronizer sleeve
and the synchronizer gear using the bearing puller
J–22888–20–A with the puller legs J–22888–35.
21. Remove the mainshaft–driven fifth–gear assembly.
22. Remove the brass synchronizer ring.
23. Remove the needle bearing, the retaining ring, and
the thrust washers.

FIVE–SPEED MANUAL TRANSAXLE 5B – 31
DAEWOO V–121 BL4
24. Remove the input drive fifth–gear snap ring.
25. Remove the input drive fifth gear using the fifth–
gear puller KM–553–A.
26. Remove the bolts and the fifth–gearshift connector
from the bearing plate using the pawl.
27. Remove the four shift–rod plugs using the shift rod
remover J–42469 and the slide hammer J–6125–B.

5B – 32IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
28. Remove the spring and the rod lock pin from the
small plug hole.
29. Remove the pin from the reverse gearshift rod/fork
assembly.
30. Remove the reverse gearshift rod/fork assembly
from the bearing plate.
31. Remove the bolts from the support bracket.