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AISIN AUTOMATIC TRANSAXLE 5A2 – 139
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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).
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5A2 – 140IAISIN AUTOMATIC TRANSAXLE
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14. Install the shim to the transaxle case.
Notice : First install a shim of the same thickness as be-
fore.
15. Install a new bearing outer race into the transaxle
case.
16. Using transaxle case oil seal installer
DW260–031–02 and a hammer, drive in a new
transaxle case oil seal.
S Oil seal in depth: 4.3 mm (0.169 in.)
17. Install the shim to the transaxle case.
Notice : First install a shim of the same thickness as be-
fore.
18. Using transaxle case outer tapered roller bearing
race adapter DW240–160 and adapter handle
DW240–170, press in a new outer tapered roller
bearing race into the transaxle case.
Notice : Press–fit the shim until it contacts the transaxle
case.
19. Install the No.1 transaxle case plate to the trans-
axle case with the bolt.
Tighten
Tighten the bolt to 9.8 NSm (87 lb–in).
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AISIN AUTOMATIC TRANSAXLE 5A2 – 141
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20. Install the differential gear to the transaxle case.
21. Install the transaxle housing and tighten the 16
bolts of the transaxle housing temporarily.
22. Tighten 8 or 9 bolts out of 16 bolts of the transaxle
housing completely.
Tighten
Tighten the bolt to 29 NSm (22 lb–ft).
23. Using differential preload adapter DW240–130, turn
the differential gear assembly right and left 2 or 3
times to allow the bearing settle.
24. Using differential preload adapter DW240–130 and
small torque wrench, measure the preload of the
differential gear.
Notice : Note down the measured valve.
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5A2 – 142IAISIN AUTOMATIC TRANSAXLE
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25. Remove the transaxle housing and install the
counter driven gear.
26. Install the transaxle housing and tighten the 16
bolts of the transaxle housing temporarily.
27. Tighten the bolts of the transaxle housing in the
same manner as in step 22.
Tighten
Tighten the bolts to 29 NSm (22 lb–in).
28. Using differential preload adapter DW240–130, turn
the differential gear assembly right and left 2 or 3
times to allow the bearing settle.
29. Using differential preload adapter DW240–130 and
a small torque wrench, measure the preload of the
differential gear. From this valve deduct the valve
measured in step 23. This is the preload of the
counter driven gear.
S Preload:
New bearing: 0.33–0.76 NSm (3.21–6.77 lb–in)
Used bearing: 0.17–0.38 NSm (1.48–3.39 lb–in)
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AISIN AUTOMATIC TRANSAXLE 5A2 – 143
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If the preload of counter driven gear does not satisfy the
specification, select the adjuster shim from the table below
and remeasure the valve. Until the valve is within the spec-
ification, repeat the procedure.
Notice : When the preload is larger than the specification,
select a thinner adjuster shim. When the preload is smaller
than specification, select a thicker adjuster shim.
S Adjuster shim thickness: mm (in.)
Mark
ThicknessMarkThickness
11.70 (0.0669)G2.17 (0.0854)
21.75 (0.0689)H2.20 (0.0866)
31.80 (0.0709)K2.25 (0.0886)
41.85 (0.0728)L2.30 (0.0906)
51.90 (0.0748)M2.35 (0.0925)
61.93 (0.0760)N2.40 (0.0945)
71.96 (0.0772)P2.45 (0.0965)
A1.99 (0.0783)Q2.50 (0.0984)
B2.02 (0.0795)R2.55 (0.1004)
C2.05 (0.0807)S2.60 (0.1024)
D2.08 (0.0819)U2.65 (0.1043)
E2.11 (0.0831)W2.70(0.1063)
F2.14 (0.0843)––
30. Using the vernier calipers, measure the free length
of the 1st & reverse brake piston return spring to-
gether with spring seat.
S Standard free length: 18.053 mm (0.71075 in.)
31. Check to see if the sliding surface of the disc, plate
and flange of 1st & reverse brake are worn or burnt.
If necessary, replace them.
Notice : If the lining of the disc is peeling off or discolored,
or even if a part of the groove is defaced, replace all discs.
Notice : Before assembling new discs, soak them in ATF
for at least 15 minutes.
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5A2 – 144IAISIN AUTOMATIC TRANSAXLE
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32. Coat 2 new O–rings with ATF, install them to the
1st & reverse piston.
33. Install the 1st & reverse brake piston to the trans-
axle case.
Notice : Be careful not to damage the O–rings of the 1st
& reverse brake piston.
34. Install the return spring to the transaxle case.
35. Install the 4 plates, 4 discs and flange.
S Install in order : P D P D P D P D
F
(P= Plate, D= Disc, F= Flange)
Page 1735 of 2643
AISIN AUTOMATIC TRANSAXLE 5A2 – 145
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36. Using 1st & reverse brake adapter DW240–070 and
brake spring compressor bolt/nut DW240–060–01,
install the snap ring.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
37. Using a dial indicator, measure the 1st & reverse
brake piston stroke while applying and releasing
392–785 kPa (57–114 psi) of compressed air.
Notice : If the piston stroke is non–standard, inspect the
discs, plates and flange. Piston stroke 0.6 1.3 mm (0.024
0.051 in.)
38. Using counter drive gear installation adapter
DW240–100, brake spring compressor bolt/nut
DW240–060–01 and brake spring compressor plate
DW240–060–02, install the counter drive gear.
Notice : Be careful not to apply excessive force to the
transaxle case.
39. Coat a new oil seal with ATF.
40. Install the oil seal to the transaxle case.
S Oil seal in depth:
A: 1 ± 0.25 mm (0.39 ± 0.0098 in.)
Page 1736 of 2643
5A2 – 146IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
41. Install the parking lock rod to the manual valve le-
ver.
42. Install a new spacer to the manual valve lever.
43. Install the manual valve lever shaft and manual
valve lever.
44. Using a pin punch and hammer, drive in a new pin.