2004 DAEWOO NUBIRA gas

AISIN AUTOMATIC TRANSAXLE 5A2 – 197
DAEWOO V–121 BL4
Disassembly Procedure
1. Write down the relative position of the primary regu-
lator valve sleeve, plug and pin.
Notice : Because the line pressure is changed by the posi-
tion of the pin and groove in the sleeve end, be sure to
check the position.
2. Remove the manual valve.
3. Remove the 5 bolts and 5 shift solenoid valves.
4. Remove the 15 bolts.
5. Remove the cover, 2 gaskets and plate.

5A2 – 200IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
7. Install the 2 gaskets, plate and lower valve body
cover.
8. First, tighten the bolts indicated by arrows tempo-
rarily and then tighten the other bolts temporarily.
9. Tighten all the bolts completely.
Tighten
Tighten the bolts to 11 NSm (97 lb–in).
S Bolt length:
Bolt A: 49 mm (1.93 in.)
Bolt B: 20 mm (0.79 in.)
Bolt C: 60 mm (2.36 in.)
10. Install the 5 shift solenoid valves with the 6 bolts.
Tighten
Tighten the bolts to 11 NSm (97 lb–in).
S Bolt length:
Bolt A: 49 mm (1.93 in.)
Bolt B: 20 mm (0.79 in.)
11. Install the manual valve.
12. Make sure that the primary regulator valve is posi-
tioned in the same place where it was removed.

5A2 – 214IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
12. Using a hammer and chisel, stake the differential
case.
13. Using a press, install the tapered roller bearing into
the differential case.
14. Using a press, install the tapered roller bearing into
the differential case.
15. Remove any formed in place gasket (FIPG) materi-
al and be careful not to get oil on the contacting
surfaces of the transaxle housing or transaxle case.
16. Install the differential to the transaxle case.

FIVE–SPEED MANUAL TRANSAXLE 5B – 11
DAEWOO V–121 BL4
BEARING PLATE
1. Strain Bolt Bridge
2. Bolt
3. Bolt
4. Bolt
5. Bearing Plate
6. Bolt
7. Pin
8. Blocking Pin
9. Compression Spring
10. Plug
11. Gear Shift Sliding Fork12. GearShift Shoe
13. Screw
14. Transaxle Cover
15. Transaxle Cover Gasket
16. Magnet
17. Bearing Plate Gasket
18. Bolt
19. Bolt
20. Bolt
21. Screw
22. Detent Sleeve

5B – 14IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
1. Gear Shift Control
2. Bolt
3. Gear Shift Tube Bellows
4. Clamp
5. Bolt
6. Gear Shift Control Mode
7. Gear Shift Guide Control
8. Pin
9. Clip
10. Bolt
11. 1st & 2nd Gear Shift Fork
12. 1st & 2nd Gear Shift Rod
13. Pin
14. 3rd & 4th Gear Shift Fork
15. 3rd & 4th Gear Shift Rod
16. Pin
17. 5th Speed Engaging Piece
18. Gear Shift Rod Pawl
19. Reverse Gear Shift Fork
20. Reverse Gear Shift Rod
21. Pin
22. Gear Shift Rod
23. Shift Finger24. Gear Shift Lever Cover
25. Gear Shift Inter Lever
26. Plate
27. Compression Spring
28. Bush
29. Retaining Ring
30. Gear Shift Cover Gasket
31. Bolt
32. Plug
33. Plug
34. Speedometer Driven Gear
35. Bolt
36. Differential Gear Cover Gasket
37. Differential Gear Cover
38. Screw
39. Backup Lamp Switch
40. O–ring
41. Pin
42. Pin
43. Sleeve
44. Bush

5B – 50IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
7. Install the transaxle cover and the transaxle cover
bolts.
Tighten
Tighten the transaxle cover bolts to 18 NSm (13 lb–ft).
8. Install the gearshift lever cover and the gearshift
lever cover bolts.
Tighten
Tighten the gearshift lever cover bolts to 22 NSm (16
lb–ft).
9. Install the transaxle into the vehicle. Refer to
”Transaxle Assembly” in this section.
DIFFERENTIAL
Tools Required
KM–520 Remover/Installer
KM–525 Installer
J–22888–20–A Bearing Puller with J–22888–35 Puller
Legs
KM–522 Installer
Disassembly Procedure
1. Remove the differential cover bolts, the differential
cover, and the differential cover gasket.
2. Remove the bearing–adjusting ring retainer plate
bolt and the bearing–adjusting ring retainer plate.

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.

CLUTCH 5C – 5
DAEWOO V–121 BL4
1. Clutch Master Cylinder
2. Nut
3. Gasket
4. Clip
5. Reservoir Hose
6. Clutch Master Cylinder Pipe
7. Clip
8. Clip
9. Bracket10. Bolt
11. Concentric Slave Cylinder
12. Concentric Slave Cylinder Pipe
13. Bolt
14. Clip
15. Hose
16. Pressure Plate
17. Clutch Disc
18. Bolt