Page 1611 of 2643
AISIN AUTOMATIC TRANSAXLE 5A2 – 21
DAEWOO V–121 BL4
Page 1612 of 2643
5A2 – 22IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
1. Planetary Ring Gear
2. O–ring
3. 1st and Reverse Brake Piston
4. O–ring
5. 1st and Reverse Brake Piston Return Spring
6. Plate
7. Disc
8. Flange
9. Snap Ring
10. Planetary Gear
11. Thrust Washer
12. No. 2 One–Way Clutch
13. Anti–Rattle Clip
14. Flange
15. Disc
16. Plate
17. 2nd Brake Piston Return Spring
18. O–ring
19. 2nd Brake Piston
20. O–ring
21. 2nd Brake Clutch Cylinder
22. Snap Ring
23. Thrust Bearing Race
24. Front Planetary Sun Gear
25. Thrust Bearing Race26. One–Way Clutch Assembly
27. Thrust Washer
28. Rear Planetary Sun Gear
29. Snap Ring
30. Flange
31. Disc
32. Plate
33. Thrust Bearing Race
34. Thrust Needle Roller Bearing
35. Forward Clutch Hub
36. Thrust Bearing Race
37. Thrust Needle Roller Bearing
38. Thrust Bearing Race
39. Forward and Reverse Clutch Assembly
40. Thrust Needle Roller Bearing
41. Snap Ring
42. O/D Brake Return Spring
43. O/D Brake Piston
44. O–ring
45. Seal Ring
46. Transaxle Rear Cover
47. Apply Gasket
48. O–ring
49. Screw Plug
Page 1613 of 2643
AISIN AUTOMATIC TRANSAXLE 5A2 – 23
DAEWOO V–121 BL4
1. Side Bearing Outer Race
2. Differential Case
3. Shim
4. Outer Tapered Roller Bearing Race
5. Counter Driven Gear
6. Oil Seal
7. Oil Pump8. Thrust Needle Roller Bearing
9. Direct Clutch Assembly
10. Thrust Bearing Race
11. Direct Clutch Hub
12. Counter Driven Gear
13. Transaxle Case Plate
14. Apply Gasket
Page 1614 of 2643
5A2 – 24IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
BEARING AND RACES INSTALLATION POSITION AND
DIRECTION
MarkFront Race Diameter : mm(in)Thrust Bearing Diameter :
mm(in)Rear Race Diameter : mm(in)
InsideOutsideInsideOutsideInsideOutside
A––32.5 (1.280)48.5 (1.909)––
B––17.8 (0.701)30.2 (1.189)20.5 (0.807)32.6 (1.283)
C19.3 (0.760)29.0 (1.142)––––
D––42.5 (1.673)57.5 (2.264)––
E34.95 (1.3670)45.50 (1.7913)33.3 (1.311)46.5 (1.831)––
F19.3 (0.760)30.6 (1.205)18.1 (0.713)29.6 (1.165)18.1 (0.713)28.2 (1.110)
G––43.2 (1.701)62.0 (2.441)––
Page 1615 of 2643
AISIN AUTOMATIC TRANSAXLE 5A2 – 25
DAEWOO V–121 BL4
DIAGNOSIS
ELECTRIC CONNECTOR VIEW
Page 1616 of 2643
5A2 – 26IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
X–1 : TCM Vehicle Side Wiring Connector
A1GroundB1R
A2Pressure Control Solenoid GroundB3Clock
A4Pressure Control SolenoidB4Hold
A5Lock–Up SolenoidB6Input Speed Sensor
A6Ignition (+)B7D
A7CAN (Low)B8N
A11Transmission Fluid Temperature SensorB16Input Speed Sensor Ground
A12Transmission Fluid Temperature Sensor
GroundB18L
A14Timing SolenoidB192
A15Shift Solenoid No.2B20P
A16Shift Solenoid No.1B22Stop Lamp Switch
A17CAN (High)B23DLC
A23GroundB25Output Speed Sensor
A24B+––
X–2 : Transmission Range (TR) Switch Connector
1P
2R
3Ground
42
5N
6ST(–)
7D
81
9ST(+)
X–4 : Output Speed Sensor Connector
1Ignition
2Ground
3Output Speed Sensor
X–3 : Transaxle Wiring Connector
1Transmission Fluid Temperature Sensor
2Timing Solenoid
3Pressure Control Solenoid
4Lock–Up Solenoid
5Shift Solenoid No.1
6Transmission Fluid Temperature Sensor
Ground
8Pressure Control Solenoid Ground
10Shift Solenoid No.2
X–5 : Input Speed Sensor
1Input Speed Sensor Ground
2Input Speed Sensor
Page 1617 of 2643
AISIN AUTOMATIC TRANSAXLE 5A2 – 27
DAEWOO V–121 BL4
WIRING HARNESS AND
CONNECTOR INSPECTION
1. Reproducing test
Perform symptom simulation test on the basis of
user’s condition. Refer to the below factors.
S Occuring–road condition, speed, accelerate,
reduce speed, straight, curve, air temperature,
weather, etc.
2. Inspect the connection condition of between con-
nectors.
Inspect the failure between connectors by visual
check and contact pressure check.
S Connector disconnected
S Terminals rusted
S Terminals deformation or loose fit
3. Inspect the Continuity of the wiring harness.
Disconnect both ends connector of wiring har-
ness, measure resistance between one connec-
tor terminal and other.
S Normal : 1Ω or less (No open circuit)
S Abnormal : Ω (Open circuit)
Notice : Measure the resistance while slightly shaking
wire harness vertically and horizontally.
It is rare case wiring harness is broken at the middle of it,
and most cases occur at the connector.
4. Inspect the short circuit of the wiring harness.
Disconnect the connectors of the wiring harness
at both ends, measure resistance between the
applicable terminals of the connector and body
earth.
S Normal : 1M Ω or higher (No short circuit)
S Abnormal : Low resistance (Short circuit)Measure the resistance between one terminal
an another terminal in the same connector.(Ex-
cept between power supply or between earth).
S Normal : 1M Ω or higher (No short circuit)
S Abnormal : Low resistance (Short circuit)
Notice : Measure the wiring harness while slightly shaking
vertically and horzontally.
It is usual case of the short circuit that wiring harness is
crowded body and clamping failure.
5. Temporary connection failure of the connector.
It is thought that temporally the connection fail-
ure of the connector is cause when you can not
decide cause of DTC detection.
Therfore make sure to inspect and clean the
connector and delete the memorized DTC.
ROAD TEST
Road test is to diagnosis failure symptom accurately and
check the failure symptom after procedure.
Confirm whether below condition before road test. Oil tem-
perature is hot condition (50°C (122°F) ~ 80°C (176°F)).
1. D range test
S Check for up–shift, down–shift, kick–down and
lock–up operation at the shift point shown in the
shift schedule.
S Check for engine brake operation.
S Check for Check abnormal shock, noise and
harshness.
2. ”P” range test
Park vehicle on a gradient (more than 5°), shift
into the ”P” range and release parking brake.
Then, check to see no moving vehicle by opera-
tion of parking lock pawl.
Page 1618 of 2643
5A2 – 28IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
FUNCTION CHECK
Confirm whether below condition before function check.
S Oil temperature is hot condition (50°C (122°F) ~
80°C (176°F)).
S Switch of A/C and light etc are off.
Stall Test
Stall test’ purpose is to inspect overall performance of A/T
and engine by measuring the stall speed in ”D” and ”R”
range.1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.
2. Fully pressed on foot brake pedal with left foot.
3. Shift into ”D” and ”R” range, fully press on accelera-
tor pedal with right foot.
Quickly read stall speed at this time.
Standards
2390 ± 150 rpm
Notice : Do not continuously run longer than 5 sec be-
cause of extreme increasing oil temp.
Make sure to keep interval for more than 1 min between
stall tests.
Result of Stall Test
Cause of Failure
Lower than standards
both ”D” and ”R”Less engine power
Torque converter one way clutch failure
Higher than standards
only ”D”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Forward clutch (C1) failure (Slipping)
No.2 One–way clutch (F2) failure
Higher than standards
only ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Reverse clutch (C3) failure (Slipping)
1st & reverse brake (B3) failure (Slipping)
Higher than standards
both ”D” and ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Oil pump failure
Oil strainer failure (clogging)
Oil leak for each range circuit
Time Lag Test
Time lag is time till slightly shock can be felt when shift le-
ver is shifted ”N” ”D” and ”N” ”R” while engine idling.
Time lag test can inspect hydraulic condition and clutch/
brake condition.
1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.
2. Measure time lag by using stop watch from moment
when shift lever is shifted in ”N” ”D” and ”N”
”R” until moment slightly shock can be felt.”N D”less than 0.7 sec
”N” ”R”less than 1.2 sec
Notice : Make sure to take 3 measurement and take the
average value.
Make sure to keep interval for more than 1 min between
time lag tests. (That purpose is to remove clutch/brake
pressure was left unfinished.)
