2004 DAEWOO NUBIRA clutch

SECTION : 5A2
AISIN AUTOMATIC TRANSAXLE
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS5A2–3 . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5A2–3. . . . . . . . . . . . . . . . . . . .
Transaxle Gear Ratio 5A2–3. . . . . . . . . . . . . . . . . . . . . .
Fluid Capacity 5A2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Specification 5A2–3. . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5A2–4. . . . . . . . . .
SPECIAL TOOLS5A2–5 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5A2–5. . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC DIAGRAMS5A2–8 . . . . . . . . . . . . . . . . . . .
Transmission Control Module (1 of 4) 5A2–8. . . . . . . .
Transmission Control Module (2 of 4) 5A2–9. . . . . . . .
Transmission Control Module (3 of 4) 5A2–10. . . . . . .
Transmission Control Module (4 of 4) 5A2–11. . . . . . .
Shift Mode Diagram 5A2–12. . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR5A2–17 . . . . . . . . . . . . . . . . . .
Shift Select Control 5A2–17. . . . . . . . . . . . . . . . . . . . . .
Automatic Transaxle Components 5A2–18. . . . . . . . .
Bearing and Races Installation Position
Direction 5A2–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5A2–25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connector View 5A2–25. . . . . . . . . . . . . . . . .
Wiring Harness and Connector Inspection 5A2–27. . .
Road Test 5A2–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Check 5A2–28. . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Inspection 5A2–30. . . . . . . . . . . . . . . . . . . . . . . . . .
On–Vehicle Repair (Matrix Chart) 5A2–34. . . . . . . . . .
DIAGNOSIS TROUBLE CODE DIAGNOSIS5A2–36 .
Diagnosis Trouble Code Chart 5A2–36. . . . . . . . . . . . .
DTC P0562 System Voltage Low 5A2–37. . . . . . . . . .
DTC P0563 System Voltage High 5A2–40. . . . . . . . . .
DTC P0601 Internal Control Module Memory
Checksum Error 5A2–43. . . . . . . . . . . . . . . . . . . . . . .
DTC P0604 Internal Transmission Control Module
(TCM) Random Access Memory (RAM)
Error 5A2–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0705 Transmission Range (TR) Switch
Circuit Malfunction 5A2–47. . . . . . . . . . . . . . . . . . . . .
DTC P0712 Transmission Fluid Temperature
(TFT) Sensor Circuit Low Input 5A2–50. . . . . . . . . .
DTC P0713 Transmission Fluid Temperature
(TFT) Sensor Circuit High Input 5A2–53. . . . . . . . . .
DTC P0717 Input Shaft Speed (ISS) Sensor
Circuit No Signal 5A2–56. . . . . . . . . . . . . . . . . . . . . . .
DTC P0722 Ouput Shaft Speed (OSS) Sensor
Circuit No Signal 5A2–59. . . . . . . . . . . . . . . . . . . . . . .
DTC P0727 Engine Speed Input Circuit No
Signal 5A2–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0741 Torque Converter Clutch (TCC)
Circuit Stuck Off 5A2–65. . . . . . . . . . . . . . . . . . . . . . .
DTC P0742 Torque Converter Clutch (TCC)
Circuit Stuck On 5A2–67. . . . . . . . . . . . . . . . . . . . . . .
DTC P0743 Torque Converter Clutch (TCC)
Electrical 5A2–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0748 Pressure Control Solenoid (PCS)
Electrical 5A2–72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0751 Shift Solenoid 1 (SS1) Stuck Off 5A2–75
DTC P0753 Shift Solenoid 1 (SS1) Electrical 5A2–77
DTC P0756 Shift Solenoid 2 (SS2) Stuck Off 5A2–80
DTC P0758 Shift Solenoid 2 (SS2) Electrical 5A2–82
DTC P0785 Timing Solenoid (ST) Electrical 5A2–85.
DTC P1781 Engine Torque Signal Error 5A2–88. . . . .
DTC P1791 Throttle Position Signal Error 5A2–91. . .
DTC P1792 Engine Coolant Temperature (ECT)
Signal Error 5A2–93. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC U2105 Can Error 5A2–95. . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR5A2–97 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 5A2–97. . . . . . . . . . . . . . . . . . .
Transaxle Fluid Level Checking Procedure 5A2–97. .
Fluid Drain Procedure 5A2–97. . . . . . . . . . . . . . . . . . . .
Locating Fluid Leaks 5A2–98. . . . . . . . . . . . . . . . . . . . .
Case Porosity Repair 5A2–98. . . . . . . . . . . . . . . . . . . . .
Fluid Cooler Flushing 5A2–99. . . . . . . . . . . . . . . . . . . . .
Control Cable Adjustment 5A2–99. . . . . . . . . . . . . . . . .

5A2 – 2IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Shift Control Lever Assembly 5A2–100. . . . . . . . . . . . .
Transmission Range (TR) Switch 5A2–101. . . . . . . . .
Shift Control Cable 5A2–104. . . . . . . . . . . . . . . . . . . . . .
Shift Select Cover 5A2–105. . . . . . . . . . . . . . . . . . . . . .
Input Shaft Speed (ISS) Sensor 5A2–106. . . . . . . . . .
Output Shaft Speed (OSS) Sensor 5A2–107. . . . . . . .
Transmission Control Module (TCM) 5A2–108. . . . . .
Fluid Cooler Inlet Pipes and Hoses 5A2–109. . . . . . . .
Fluid Cooler Outlet Pipes and Hoses 5A2–110. . . . . .
Transaxle Assembly 5A2–111. . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 5A2–117. . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Disassembly 5A2–117. . . . . . . . . . .
Major Component Assembly 5A2–137. . . . . . . . . . . . .
Oil Pump 5A2–167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Clutch 5A2–171. . . . . . . . . . . . . . . . . . . . . . . . . . .
Planetary Ring Gear 5A2–178. . . . . . . . . . . . . . . . . . . .
One–Way Clutch 5A2–180. . . . . . . . . . . . . . . . . . . . . . .
Forward and Reverse Clutch 5A2–183. . . . . . . . . . . . .
Counter Driven Gear 5A2–192. . . . . . . . . . . . . . . . . . . .
Valve Body 5A2–195. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Case 5A2–208. . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION5A2–218 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transaxle Description 5A2–218. . . . . . . . . . . . . . . . . . .
Electronical Components 5A2–218. . . . . . . . . . . . . . . .
Hydraulic Control System 5A2–221. . . . . . . . . . . . . . . .
Automatic Transaxle System 5A2–222. . . . . . . . . . . . .

AISIN AUTOMATIC TRANSAXLE 5A2 – 5
DAEWOO V–121 BL4
SPECIAL TOOLS
SPECIAL TOOLS TABLE
DW260–021–02
Automatic
Transaxle
Overhaul
Fixture
DW240–020
Brake/Clutch
Spring Compressor
DW240–030
Forward Clutch
Adapter
DW240–040
Direct Clutch
Adapter
DW240–050
Overdrive
Brake Adapter
DW240–060–01
Brake Spring
Compressor
Bolt/Nut
DW240–060–02
Brake Spring
Compressor
Plate
DW240–070
1st/Reverse
Brake Adapter

5A2 – 20IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
1. Transaxle Housing
2. Oil Seal
3. Oil Reservoir Plate
4. Transaxle Oil Apply Pipe
5. Differential Gear Oil Apply Pipe
6. Transaxle Oil Apply Pipe Clamp
7. Spring
8. Check Valve Pipe Clamp
9. Apply Gasket
10. Brake Drun Gasket
11. Transaxle Wire
12. O–ring
13. Valve Body
14. Parking Lock Pawl
15. Parking Lock Pawl Shaft
16. Torsion Spring
17. Manual Valve lever Shaft
18. Manual Valve Lever
19. Parking Lock Rod
20. Parking Lock Pawl Bracket
21. Manual Detent Spring
22. Pin
23. Spacer24. Oil Seal
25. Transmission Range (TR) Switch
26. Lock Washer
27. Control Lever
28. Washer
29. Gasket
30. Oil Strainer
31. Oil Pan
32. Gasket
33. Magnet
34. Direct Clutch Accumulator Piston
35. O–ring
36. Spring
37. O–ring
38. Forward Clutch Accumulator Piston
39. O–ring
40. Spring
41. O–ring
42. Overdrive Brake Accumulator Piston
43. O–ring
44. O–ring
45. Spring

5A2 – 22IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
1. Planetary Ring Gear
2. O–ring
3. 1st and Reverse Brake Piston
4. O–ring
5. 1st and Reverse Brake Piston Return Spring
6. Plate
7. Disc
8. Flange
9. Snap Ring
10. Planetary Gear
11. Thrust Washer
12. No. 2 One–Way Clutch
13. Anti–Rattle Clip
14. Flange
15. Disc
16. Plate
17. 2nd Brake Piston Return Spring
18. O–ring
19. 2nd Brake Piston
20. O–ring
21. 2nd Brake Clutch Cylinder
22. Snap Ring
23. Thrust Bearing Race
24. Front Planetary Sun Gear
25. Thrust Bearing Race26. One–Way Clutch Assembly
27. Thrust Washer
28. Rear Planetary Sun Gear
29. Snap Ring
30. Flange
31. Disc
32. Plate
33. Thrust Bearing Race
34. Thrust Needle Roller Bearing
35. Forward Clutch Hub
36. Thrust Bearing Race
37. Thrust Needle Roller Bearing
38. Thrust Bearing Race
39. Forward and Reverse Clutch Assembly
40. Thrust Needle Roller Bearing
41. Snap Ring
42. O/D Brake Return Spring
43. O/D Brake Piston
44. O–ring
45. Seal Ring
46. Transaxle Rear Cover
47. Apply Gasket
48. O–ring
49. Screw Plug

AISIN AUTOMATIC TRANSAXLE 5A2 – 23
DAEWOO V–121 BL4
1. Side Bearing Outer Race
2. Differential Case
3. Shim
4. Outer Tapered Roller Bearing Race
5. Counter Driven Gear
6. Oil Seal
7. Oil Pump8. Thrust Needle Roller Bearing
9. Direct Clutch Assembly
10. Thrust Bearing Race
11. Direct Clutch Hub
12. Counter Driven Gear
13. Transaxle Case Plate
14. Apply Gasket

5A2 – 28IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
FUNCTION CHECK
Confirm whether below condition before function check.
S Oil temperature is hot condition (50°C (122°F) ~
80°C (176°F)).
S Switch of A/C and light etc are off.
Stall Test
Stall test’ purpose is to inspect overall performance of A/T
and engine by measuring the stall speed in ”D” and ”R”
range.1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.
2. Fully pressed on foot brake pedal with left foot.
3. Shift into ”D” and ”R” range, fully press on accelera-
tor pedal with right foot.
Quickly read stall speed at this time.
Standards
2390 ± 150 rpm
Notice : Do not continuously run longer than 5 sec be-
cause of extreme increasing oil temp.
Make sure to keep interval for more than 1 min between
stall tests.
Result of Stall Test
Cause of Failure
Lower than standards
both ”D” and ”R”Less engine power
Torque converter one way clutch failure
Higher than standards
only ”D”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Forward clutch (C1) failure (Slipping)
No.2 One–way clutch (F2) failure
Higher than standards
only ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Reverse clutch (C3) failure (Slipping)
1st & reverse brake (B3) failure (Slipping)
Higher than standards
both ”D” and ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Oil pump failure
Oil strainer failure (clogging)
Oil leak for each range circuit
Time Lag Test
Time lag is time till slightly shock can be felt when shift le-
ver is shifted ”N”  ”D” and ”N”  ”R” while engine idling.
Time lag test can inspect hydraulic condition and clutch/
brake condition.
1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.
2. Measure time lag by using stop watch from moment
when shift lever is shifted in ”N”  ”D” and ”N” 
”R” until moment slightly shock can be felt.”N  D”less than 0.7 sec
”N”  ”R”less than 1.2 sec
Notice : Make sure to take 3 measurement and take the
average value.
Make sure to keep interval for more than 1 min between
time lag tests. (That purpose is to remove clutch/brake
pressure was left unfinished.)

AISIN AUTOMATIC TRANSAXLE 5A2 – 29
DAEWOO V–121 BL4
Result of Time Lag TestCause of Failure
Longer than standards ”N”  ”D”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Forward Clutch (C1) failure (Slipping)
Timing solenoid failure
Oil leak for ”D” range circuit
Longer than standards ”N”  ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Reverse clutch (C3) failure (slipping)
1st & reverse brake (B3) failure (slipping)
Oil leak for ”R” range circuit
Hydraulic Test
Hydraulic test can inspect working condition inside A/T by
measuring line pressure in ”D” / ”R” range and ”idle” / ”stall”
condition.
1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.2. Install oil pressure gage adapter DW240–010–02 to
test hole for line pressure.
3. Fully pressed on foot brake pedal with left foot, shift
into ”D” and ”R” range and measure line pressure
”idle” / ”stall” condition.
Line pressure
Mpa (kgf/cm
2)
DR
Engine idle0.37 (3.9)
–0.14 (4.2)0.59 (6.0)
–0.68 (6.9)
Engine stall1.10 (11.3)
–1.23 (12.5)1.58 (16.2)
–1.83 (18.6)
Notice : Do not continuously run longer than 5 sec be-
cause of extreme increasing oil temp.
Make sure to keep interval for more than 1 min between
stall tests.
Make sure to check no oil leak after installing oil pressure
gage adapter.
Result of Hydraulic Test
Cause of Failure
Higher than standards
both ”D and ”R”Pressure control solenoid (PCS) failure
Primary regulator valve failure
Lower than standards
both ”D and ”R”Pressure control solenoid (PCS) failure
Primary regulator valve failure
Oil pump failure
Oil strainer failure (clogging)
Oil leak for each range circuit
Lower than standards
only ”D”D” hydraulic circuit failure
Forward clutch (C1) failure
Lower than standards
only ”R””R” hydraulic circuit failure
Reverse clutch (C3) failure
1st and reverse brake (B3) failure