2004 DAEWOO NUBIRA automatic transaxle

5A1 – 198IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
PARK/NEUTRAL START SWITCH
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the park/neutral position switch electri-
cal connector.
3. Disconnect the shift control cable and the retaining
clip.
4. Remove the shift lever nut and the shift lever.
5. Remove the park/neutral start switch.
Tools Required
DW260–050 P/N Switch Installer
Installation Procedure
1. Install the park/neutral start switch.
Tighten
Tighten the bolts to 10 NSm (89 lb–in).
2. Adjust the park/neutral switch using the P/N switch
installer DW260–050.
Notice : When install the park/neutral switch, using the
special service tools and the shift lever must be positioned
”Neutral”.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 199
DAEWOO V–121 BL4
3. Install the shift lever and the shift lever nut.
Tighten
Tighten the shift lever nut to 10 NSm (89 lb–in).
4. Connect the shift control cable and the retaining
clip.
5. Connect the park/neutral position switch electrical
connector.
6. Connect the negative battery cable.
OIL COOLER PIPES/HOSES
Removal Procedure
Important : Place a drip pan under the hoses to catch the
fluid that will run out of the lines.
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
4. Remove the oil cooler outlet pipe bolt from the right
lower side of the radiator.
5. Remove the oil cooler outlet pipe bracket bolt.
6. Remove the oil cooler outlet pipe bolt from the
transaxle side.
7. Remove the oil cooler outlet pipe assembly.

5A1 – 200IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
8. Remove the oil cooler inlet pipe bolt from the left
lower side of the radiator.
9. Remove the oil cooler inlet pipe bolt from the trans-
axle side.
10. Remove the oil cooler inlet pipe assembly.
Installation Procedure
1. Install the oil cooler inlet pipe assembly and the
bolts.
Tighten
Tighten the oil cooler inlet pipe bolts to 35 NSm (26 lb–
ft).
2. Install the oil cooler outlet pipe assembly and the
bolts.
Tighten
Tighten the oil cooler outlet pipe bolts to 35 NSm (26
lb–ft).
3. Refill the transaxle fluid. Refer to ”Transaxle Fluid
Checking Procedure” in this section.
4. Install the engine under cover. Refer to Section 9N,
Frame and Underbody.
5. Connect the negative battery cable.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 201
DAEWOO V–121 BL4
DRIVE AXLE OIL SEAL
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the drive axles. Refer to Section 3A, Auto-
matic Transaxle Drive Axle.
Notice : Be careful not to damage the bore of the transaxle
case.
3. Remove the transaxle drive seal using a screwdriv-
er. If necessary, crush the seal first with the screw-
driver in order to loosen the seal from the case.
Tools Required
DW260–030 Axle Seal Installer
Installation Procedure
1. Install the transaxle drive seal using the axle seal
installer DW260–030.
2. Install the drive axles. Refer to Section 3A, Auto-
matic Transaxle Drive Axle.
3. Connect the negative battery cable.
OIL PAN, OIL PAN GASKET
Tools Required
DW260–070 Plug Remover/Installer
Removal Procedure
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
4. Place a fluid container below the fluid drain plug.
5. Remove the transaxle fluid drain plug using the
plug remover/installer DW260–070 and drain the
transaxle fluid.
6. Remove the oil cooler inlet and outlet pipes. Refer
to ”Oil Cooler Pipe/Hose” in this section.

5A1 – 202IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
7. Remove the oil pan and oil pan gasket.
Installation Procedure
1. Install the oil pan, oil pan gasket and bolts.
Tighten
Tighten the oil pan bolts to 6 NSm (53 lb–in).
2. Install the oil cooler inlet and outlet pipes. Refer
to”Oil Cooler Pipe/Hose” in this section.
3. Install the transaxle fluid drain plug using the plug
remove/installer DW260–070.
4. Install the engine under cover. Refer to Section 9N,
Frame and Underbody.
5. Refill the transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
6. Connect the negative battery cable.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 203
DAEWOO V–121 BL4
CONTROL VALVE BODY ASSEMBLY
Tools Required
DW260–070 Plug Remover/Installer
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the transaxle wiring harness and the
park/neutral position switch electrical connector.
3. Raise and suitably support the vehicle.
4. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
5. Remove the transaxle fluid drain plug using the
plug remover/installer DW260–070 and drain the
transaxle fluid.
6. Remove the oil pan, oil pan gasket. Refer to ”Oil
Pan, Oil Pan Gasket” in this section.
7. Remove the valve body mounting bolts.
8. Remove the automatic transmission input speed
sensor mounting bolt.
9. Remove the automatic transmission output speed
sensor mounting bolt.

5A1 – 204IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
10. Remove the control valve body.
Installation Procedure
1. Install the control valve body and the bolts.
Tighten
Tighten the valve body mounting bolts to 8 NSm (71
lb–in).
2. Install the input speed sensor mounting bolt.
Tighten
Tighten the input speed sensor mounting bolt to 8
NSm (71 lb–in).
3. Install the output speed sensor mounting bolt.
Tighten
Tighten the output speed sensor mounting bolt to 6
NSm (53 lb–in).
4. Install the oil pan and oil pan gasket. Refer to ”Oil
Pan Gasket” in this section.
5. Install the transaxle fluid drain plug using the plug
remove/installer DW260–070.
6. Install the engine under cover. Refer to Section 9N,
Frame and Underbody.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 205
DAEWOO V–121 BL4
7. Lower the vehicle.
8. Connect the transaxle wiring harness and the PNP
switch electrical connector.
9. Refill the transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
10. Connect the negative battery cable.
LEFT TRANSAXLE MOUNTING
BRACKET
Tools Required
DW110–060 Engine Support Fixture
Removal Procedure
1. Remove the battery. Refer to Section 1E, Engine
Electrical.
2. Install the engine support fixture DW110–060.
3. Remove the left transaxle mounting bolts.
4. Remove the left transaxle mount bracket cage bolts
and nut.
5. Remove the transaxle mounting bracket.