2004 DAEWOO NUBIRA section 9G

5A1 – 212IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
UNIT REPAIR
TORQUE CONVERTER
Disassembly and Assembly Procedure
1. Remove the transaxle assembly. Refer to ”Trans-
axle Assembly” in this section.
2. Remove the torque converter assembly.
3. Installation should follow the removal procedure in
the reverse order.
TRANSAXLE HOLDING FIXTURE
ASSEMBLY
Tools Required
DW260–020 Transaxle Support Fixture
CAUTION : To reduce the possibility of personal inju-
ry or transaxle damage, make sure, when doing the
next step, that all of the bolts for the support fixture
are installed as shown, and that the bolts are tight-
ened to 11 NSm (98 lb–in).
Disassembly and Assembly Procedure
1. Install the transaxle support fixture DW260–020
onto the transaxle.
2. Torque the support fixture bolts to 11 NSm (98 lb–
in).
3. Position the transaxle with the rear cover facing up.
VALVE BODY
Disassembly and Assembly Procedure
1. Remove the oil pan bolts and oil pan.
2. Remove the oil pan gasket.
Installation Notice
Tighten the oil pan bolts to 6 NSm (53 lb–in).

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 213
DAEWOO V–121 BL4
3. Remove valve body fixing bolts and transaxle input
speed sensor bolt on the valve body.
4. Remove the holder for the transaxle input speed
sensor.
Installation Notice
Tighten the bolts to 8 NSm (71 lb–in).
5. Tilt the valve body.
6. Remove the fastening screw for the output speed
sensor under the valve body assembly.
7. Lever the cable out of the retaining clip and pull out
the output speed sensor.
8. Installation should follow the removal procedure in
the reverse order.
Installation Notice
Tighten the screw to 6 NSm (53 lb–in).
REAR COVER
Disassembly and Assembly Procedure
1. Removal the valve body assembly. Refer to ”Valve
Body Removal” in this section.
2. Pull out sealing sleeve (brake C) with a kind of nail.
3. Turn transaxle by 90°.
4. Remove the rear cover bolts.
5. Hit the rear cover rightly.
6. Remove the cover.
7. Installation should follow the removal procedure in
the reverse order.
Installation Notice
Tighten the rear cover bolts to 23 NSm (17 lb–ft).

5A1 – 214IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
CLUTCH B/E
Tools Required
DW260–140 Clutch B Stop Ring Remover/Installer
DW260–150 Clutch B Stop Ring Remover/Installer
Disassembly and Assembly Procedure
1. Remove the rear cover. Refer to ”Rear Cover Re-
moval” in this section.
2. Remove the two sealing rings(clutch B/E).
3. Take out input shaft with clutch B/E.
4. Remove needle bearing and thrust washer.
5. Remove shim.
6. Take out the retaining snap ring.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 215
DAEWOO V–121 BL4
7. Take out the piston B.
8. Remove disc set B.
9. Take out the piston rings.
Removal Notice
S Remove the rectangular–section ring for the in-
put shaft and the retaining ring.
10. Remove inner disc carrier E and needle roller thrust
bearing.

5A1 – 220IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
PLANETARY GEAR SET
Disassembly and Assembly Procedure
1. Remove the clutch B/E. Refer to ”Clutch B/E” in
this section.
2. Remove the rear sun gear.
3. Remove the planetary gear set.
4. Remove snap ring from front ring gear.
5. Take out rear planetary gear set.

5A1 – 224IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
10. Turn the disc carrier C/D by 180°.
11. Using assembly bracket Press down cup spring and
take out the snap ring.
12. Remove the disc set D.
13. Installation should follow the removal procedure in
the reverse order.
DIFFERENTIAL
Disassembly and Assembly Procedure
1. Remove the torque converter housing. Refer to
”Torque Converter” in this section.
2. Lift out the differential.
3. Installation should follow the removal procedure in
the reverse order.
Removal Notice
S Don’t disassemble the differential to avoid incorrect
operation.
SIDE SHAFT
Disassembly and Assembly Procedure
1. Remove the differential. Refer to ”Differential” in
this section.
2. Tilt and remove the side shaft.
3. Installation should follow the removal procedure in
the reverse order.
Removal Notice
S Don’t disassemble the differential to avoid incorrect
operation.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 225
DAEWOO V–121 BL4
BRAKE F, SLOTTED NUT
Tools Required
DW260–060 Brake F Split Stop Ring Remover
Disassembly and Assembly Procedure
1. Remove the side shaft. Refer to ”Side Shaft” in this
section.
2. Take OFF the disc set and the brake F inner disc
carrier.
3. Mount fixture and remove the brake F split stop
ring.
4. Remove the fixture and take off the cup spring.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 229
DAEWOO V–121 BL4
PARKING LOCK SYSTEM
Disassembly and Assembly Procedure
1. Remove the parking lock assembly.
S Parking lock system is consist of parking pawl,
leg spring, support bolt.
2. Installation should follow the removal procedure in
the reverse order.
BEARING PLATE(WITH SPUR GEAR)
ASSEMBLY
Disassembly and Assembly Procedure
1. Remove the piston F. Refer to ”Brake F” in this
section.
2. Remove the bearing plate bolts and bearing plate.
3. Installation should follow the removal procedure in
the reverse order.
Installation Notice
Tighten
Tighten the bearing plate bolts to 27 NSm (17 lb–ft).
OIL PUMP ASSEMBLY
Disassembly and Assembly Procedure
1. Remove the oil pump housing bolts.
2. Using the plastic hammer. Take out the oil pump
housing.
Installation Notice
Tighten
Tighten the oil pump housing bolts 10 NSm (89 lb–in).
3. Remove the stator shaft bolts.