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5A1 – 220IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
PLANETARY GEAR SET
Disassembly and Assembly Procedure
1. Remove the clutch B/E. Refer to ”Clutch B/E” in
this section.
2. Remove the rear sun gear.
3. Remove the planetary gear set.
4. Remove snap ring from front ring gear.
5. Take out rear planetary gear set.
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ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 221
DAEWOO V–121 BL4
6. Remove the axial needle bearing.
7. Take out front gear set with rear ring gear, front sun
gear and oil trays.
8. Take oil trays and front sun gear off the planetary
gear set.
9. Installation should follow the removal procedure in
the reverse order.
BRAKE C/D
Tools Required
DW260–160 Brake C/D Snap Ring Remover/Installer
Disassembly and Assembly Procedure
1. Take snap ring out of transaxle housing.
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5A1 – 222IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
2. Release cylinder with piston C by applying com-
pressed air to the feed bore .
3. Remove cylinder with piston C.
4. Take disc carrier C/D and spring disc out of trans-
axle housing.
5. Release cylinder with piston D by applying com-
pressed air to the feed bore.
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ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 223
DAEWOO V–121 BL4
6. Remove cylinder with piston C.
7. Separate between piston C and cylinder C.
8. Take snap ring out of brake C.
9. Remove the disc set C.
Installation Notice
S Transaxle has two lined clutch discs and one
steel clutch disc. The lined discs must be
installed in such a way that the lining faces the
steel disc.
S Insert the fitting keys into the appropriate
grooves.
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5A1 – 224IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
10. Turn the disc carrier C/D by 180°.
11. Using assembly bracket Press down cup spring and
take out the snap ring.
12. Remove the disc set D.
13. Installation should follow the removal procedure in
the reverse order.
DIFFERENTIAL
Disassembly and Assembly Procedure
1. Remove the torque converter housing. Refer to
”Torque Converter” in this section.
2. Lift out the differential.
3. Installation should follow the removal procedure in
the reverse order.
Removal Notice
S Don’t disassemble the differential to avoid incorrect
operation.
SIDE SHAFT
Disassembly and Assembly Procedure
1. Remove the differential. Refer to ”Differential” in
this section.
2. Tilt and remove the side shaft.
3. Installation should follow the removal procedure in
the reverse order.
Removal Notice
S Don’t disassemble the differential to avoid incorrect
operation.
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ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 225
DAEWOO V–121 BL4
BRAKE F, SLOTTED NUT
Tools Required
DW260–060 Brake F Split Stop Ring Remover
Disassembly and Assembly Procedure
1. Remove the side shaft. Refer to ”Side Shaft” in this
section.
2. Take OFF the disc set and the brake F inner disc
carrier.
3. Mount fixture and remove the brake F split stop
ring.
4. Remove the fixture and take off the cup spring.
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5A1 – 226IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
5. Release the piston F by applying compressed air to
the bore.
6. Remove piston F and bearing plate with spur gear.
7. Installation should follow the removal procedure in
the reverse order.
Removal Notice
Since the bearing set is tight, press the bearing plate up-
ward from underneath to remove it.
ORIGIN
ON/OFF– 12.54
+ / –
ORIGIN
ON/OFF– 12.54
+ / –
Tools Required
DW 260–110 Brake F Disc Clearance Measuring Bar
Measuring Installation Space F
1. Using a depth gauge, measuring from the transaxle
housing sealing surfaces to the piston’s disc sup-
port surface at two opposing points = M1, M2
2. Average the measurement values M1, M2 = BF
S CALCULATION
BF = (M1+M2)/2
S CALCULATION
M1 = 18.6mm
M2 = 18.8mm
BF = 18.7mm
Determining Adjusting Disc F
1. Calculate the test dimension PF (PF = BF – MF)
BF = installation space
MF = disc set thickness (assume 14.50mm)
S EXAMPLE
BF = 18.70mm
MF = 14.50mm
PE = 4.2mm
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ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 227
DAEWOO V–121 BL4
2. Find the disc set’s thickness. Refer to the below
table.
PF
Disc set’s Thickness
3.01~3.19mm1.8mm
3.20~3.48mm2.1mm
3.49~3.88mm2.5mm
3.89~4.08mm2.7mm
4.09~4.30mm3.0mm
PE is 4.20mm so, the disc set’s thickness is
3.0mm.
3. Replace clutch B’s setting disc. (3.0mm)
TORQUE CONVERTER HOUSING
Disassembly and Assembly Procedure
1. Remove the torque converter bolts.
2. Hit the torque converter housing lightly.
3. Remove the torque converter housing.
Installation Notice
S First pre–tighten the bolts in the following or-
der.(7,20)(12,23)(16,4)
Tighten
Tighten the bolts to 15 NSm (11 lb–ft).
S Then, tighten the bolts in the following order. (15,3)
(16,4) (14,5) (13,23) (12,22)(11,21)
(10,20) (9,19) (8,18) (7,17) (6) (1,2)
S Last, in numerical order, tighten the bolts all the
way.(123)
Tighten
Tighten the bolts to 23 NSm (17 lb–ft).
4. Take out the metal gasket.
5. Take out the paper gasket.
6. Remove the oil filter bolt and oil filter.
Installation Notice
Tighten
Tighten the oil filter bolt to 10 NSm (89 lb–in).