2004 DAEWOO NUBIRA clutch

FIVE–SPEED MANUAL TRANSAXLE 5B – 23
DAEWOO V–121 BL4
18. Remove the seven transaxle lower retaining bolts.
19. Remove the transaxle.
Notice : Rest the transaxle only in an upright position.
20. Slide the transaxle sideways away from the engine
block.
21. Lower the transaxle.
Installation Procedure
1. Support the transaxle with a transaxle support jack.
2. Install the transaxle by inserting the transaxle input
shaft into the clutch disc and sliding the transaxle
sideways into the engine block.
3. Install the seven transaxle lower retaining bolts.
Tighten
Tighten the transaxle lower retaining bolts(a) to 73
NSm ( 54 lb–ft ).
Tighten the transaxle lower retaining bolt(b) to 31 NSm
( 23 lb–ft ).
Tighten the transaxle lower retaining bolts(c) to 21
NSm ( 15 lb–ft ).

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.

FIVE–SPEED MANUAL TRANSAXLE 5B – 49
DAEWOO V–121 BL4
7. Remove the clutch–release bearing and the clutch–
release bearing guide. Refer to Section 5C, Clutch.
8. Remove the speedometer–driven gear bolt and the
speedometer–driven gear from the transaxle hous-
ing.
Assembly Procedure
1. Install the speedometer–driven gear bolt and the
speedometer–driven gear into the transaxle hous-
ing.
Tighten
Tighten the speedometer–driven gear bolt to 5 NSm
(44 lb–in)
2. Install the clutch–release bearing guide and the
clutch–release bearing. Refer to Section 5C,
Clutch.
3. Install the backup lamp switch into the transaxle
housing.
Tighten
Tighten the backup lamp switch to 20 NSm (15 lb–ft).
4. Install the differential into the transaxle housing.
Refer to ”Differential” in this section.
5. Install the bearing plate, with the shafts attached.
6. Install the bearing plate bolts.
Tighten
Tighten the bearing plate bolts to 22 NSm (16 lb–ft).

SECTION : 5C
CLUTCH
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 terminals. 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
SPECIFICATIONS5C–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5C–1. . . . . . . . . . .
SPECIAL TOOLS5C–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5C–2. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5C–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Operation 5C–2. . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR5C–4 . . . . . . . . . . . . . . . . . . . .
Clutch Components 5C–4. . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR5C–6 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 5C–6. . . . . . . . . . . . . . . . . . . . .
Clutch Pedal 5C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Pedal Adjustment 5C–7. . . . . . . . . . . . . . . . . . . .
Clutch Release Point Adjustment 5C–8. . . . . . . . . . . .
Air Bleeding 5C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Plate and Clutch Disc 5C–8. . . . . . . . . . . . . .
Clutch Master Cylinder Assembly 5C–10. . . . . . . . . . .
Concentric Slave Cylinder 5C–12. . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION5C–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving Members 5C–14. . . . . . . . . . . . . . . . . . . . . . . . .
Driven Members 5C–14. . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Members 5C–14. . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Clutch Master Cylinder nuts2216–
Concentric Slave Cylinder Retaining Bolts7–62
Concentric Slave Cylinder–to–Clutch Oil Pipe Screw1511–
Pressure Plate–to–Flywheel Bolts1511–

5C – 2ICLUTCH
DAEWOO V–121 BL4
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–42474
Clutch Arbor
DIAGNOSIS
CLUTCH OPERATION
Intermittent Clutch Operation
ChecksAction
Check for the driver improperly operating the vehicle.Correct the driver’s operation of the vehicle as necessary.
Check for the improper clutch pedal play.Adjust the clutch pedal play.
Check for the insufficient oil or the leak at oil pressure line.Repair the leak or add the oil.
Check for a warped or worn clutch disc.Replace the clutch disc.
Check for worn splines on the input shaft.Repair or Replace the splines on the input shaft.
Check for a weak diaphragm spring.Replace the pressure plate.
Clutch Slipping
ChecksAction
Check for a stuck concentric slave cylinder.Replace the concentric slave cylinder.
Check for improper return of clutch oil.Perform the air bleeding.
Check for a worn clutch disc or oil contamination.Replace the clutch disc.
Check for a warped pressure plate.Replace the pressure plate.

CLUTCH 5C – 3
DAEWOO V–121 BL4
Clutch Vibration
ChecksAction
Check for a contaminated or warped flywheel.Repair or replace the flywheel.
Check for a weak diaphragm spring.Replace the pressure plate.
Check for a oily contamination of clutch disc.Replace the clutch disc.
Check for worn splines on the input shaft.Replace the splines on the input shaft.
Check for a warped pressure plate or flywheel.Replace the pressure plate or flywheel.
Hard Pedal Effort
ChecksAction
Check for bad lubrication of clutch pedal shaft.Apply the grease or repair it.
Check for a clogged pipe.Inspect or replace the clogged pipe.
Check for a stuck concentric slave cylinder.Replace the concentric slave cylinder.
Noise in Clutch Pedal
ChecksAction
Check for insufficient lubrication of clutch pedal bushing.Lubricate the clutch pedal bushing.
Check for interference of clutch pedal return spring.Remove and reinstall the clutch pedal return spring.

5C – 4ICLUTCH
DAEWOO V–121 BL4
COMPONENT LOCATOR
CLUTCH COMPONENTS
1. Clutch Pedal
2. Bolt
3. Nut
4. Lock Nut
5. Clutch Pedal Buffer
6. Nut
7. Clutch Pedal Brace8. E–Ring
9. Pin
10. E–Ring
11. Clutch Master Cylinder
12. Clutch Pedal Shaft
13. Turn–over Spring

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