2004 DAEWOO NUBIRA gear lever

5B – 6IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
SYMPTOM DIAGNOSIS
ChecksAction
Check for a knock at low speeds.S Replace any worn drive axle CV joints.
S Replace any worn side gear hub.
Check for a noise most pronounced on turns.S Correct any abnormalities in the differential gear.
Check for a clunk upon acceleration or deceleration.S Tighten any loose engine mounts.
S Replace any worn drive axle inboard joints.
S Replace any worn differential pinion shaft in the
case.
S Replace any worn side gear hub in the case.
Check for a clunking noise in turns.S Replace any worn outboard CV joint.
Check for a vibration.S Replace any rough wheel bearing.
S Replace any bent drive axle shaft.
S Replace any out–of–round tires.
S Balance any unbalanced tire.
S Replace any worn CV joint in the drive axle shaft.
S Correct an excessive drive axle angle by adjusting
the trim height.
Check for a noise in the NEUTRAL gear with the engine
running.S Replace any worn cluster bearing shaft.
S Replace any worn clutch–release bearing.
S Replace any worn input shaft cluster gears.
S Replace any worn first–gear/bearing.
S Replace any worn second–gear/bearing.
S Replace any worn third–gear/bearing.
S Replace any worn fourth–gear/bearing.
S Replace any worn fifth–gear/bearing.
S Replace any worn mainshaft bearings.
Check for a noise in the first gear (1) only.S Replace any chipped, scored, or worn first–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn first–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the second gear (2) only.S Replace any chipped, scored, or worn second–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn second–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the third gear (3) only.S Replace any chipped, scored, or worn third–gear
constant mesh gears.
S Replace any worn third–fourth gear synchronizer.
S Replace any worn third–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.

FIVE–SPEED MANUAL TRANSAXLE 5B – 7
DAEWOO V–121 BL4
Checks Action
Check for a noise in the fourth gear (4) only.S Replace any chipped, scored, or worn fourth gear or
output gear.
S Replace any worn third–fourth gear synchronizer.
S Replace any worn fourth–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the fifth gear (5) only.S Replace any chipped, scored, or worn fifth gear or
output gear.
S Repair any worn fifth–gear synchronizer.
S Replace any worn fifth–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the reverse (R) gear only.S Replace any chipped, scored, or worn reverse idler
gear, idler–gear bushing, input gear, or output gear.
S Replace any worn first–second gear synchronizer.
S Replace any worn output gear.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
Check for a noise in all gears.S Add sufficient lubricant.
S Replace any worn bearings.
S Replace any chipped, scored, or worn input–gear
shaft or output–gear shaft.
Check for the transaxle slipping out of gear.S Adjust or replace the linkage, as needed.
S Adjust, repair, or replace any binding shift linkage.
S Tighten or replace the input–gear bearing retainer, as
needed.
S Repair or replace any worn or bent shift fork.
Check for a leak in the area of the clutch.S Repair the transaxle casing.
S Replace any damaged release bearing guide.
Check for a leak at the center of the transaxle.S Repair the transaxle casing.
S Repair the shift mechanism.
S Replace the damaged backup lamp switch.
Check for a leak at the differential.S Adjust or replace the bearing retainers.
S Tighten or replace the differential cover.
S Adjust or replace the drive axle shaft seals.

5B – 8IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
Checks Action
Check for a hard shift.S Replace any damaged release–bearing guide.
S Adjust, repair, or replace the shift mechanism.
S Adjust, repair, or replace the clutch–release system.
S Replace any chipped, scored, or worn fifth–gear syn-
chronizer.
S Replace any chipped, scored, or worn first–second
gear synchronizer.
S Replace any worn third–fourth gear synchronizer.
S Adjust, repair, or replace the shift lever and the rods.
Check for a clashing of gears.S Replace any damaged release–bearing guide.
S Adjust, repair, or replace the clutch–release system.
S Replace the chipped, scored, or worn input shaft/
gear–cluster gears.
S Replace any worn fifth–gear synchronizer.
S Replace any worn fifth–gear/bearing.
S Replace any worn first–gear/bearing.
S Replace any worn first–second gear synchronizer.
S Replace any worn second–gear/bearing.
S Replace any worn third–gear/bearing.
S Replace any worn third–fourth synchronizer.
S Replace any worn fourth–gear/bearing.
S Replace any worn reverse–idler gear.

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

FIVE–SPEED MANUAL TRANSAXLE 5B – 15
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CHECKING FLUID LEVEL
1. With the vehicle on a level surface and the fluid in
the transaxle cold, remove the filler plug and check
the fluid level. The fluid should come to the bottom
edge of the plug hole.
2. If the level is low, add SAE 80 manual transaxle
fluid through the filler plug hole until the fluid begins
to run out.
3. Reinstall the filler plug and tighten it securely.
4. If the fluid is contaminated, drain the oil after re-
moving the differential gear cover.
SHIFT LINKAGE ADJUSTMENT
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
Important : All the gears must be easy to engage when
the vehicle is stationary, the engine is running, and the
clutch is disengaged.
3. Loosen the rod clamp bolt.

5B – 16IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
4. Remove the adjustment hole plug from the shift
lever cover.
5. Turn the gearshift rod and fully insert a 5 mm (0.2
inch) gauge pin into the adjustment hole.
6. Remove the boot from the console.
7. Pull the boot upward to expose the shift control le-
ver mechanism.
8. Position the gearshift lever close to left side of the
NEUTRAL position.
9. Insert a 5 mm (0.2 inch) gauge pin into the holes to
align the gearshift lever with the gearshift lever
housing.
10. Tighten the rod clamp bolt.
Tighten
Tighten the rod clamp bolt to 14 NSm (124 lb–in).
11. Remove .the 5 mm (0.2 inch) gauge pin from the
adjustment hole.
12. Install the adjustment hole plug.
13. Remove the 5 mm (0.2 inch) gauge pin from the
gearshift lever.
14. Install the boot to the console.
15. Connect the negative battery cable.

FIVE–SPEED MANUAL TRANSAXLE 5B – 17
DAEWOO V–121 BL4
GEARSHIFT LEVER
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
Removal Procedure
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
3. Disconnect the boot from the console cover.
4. Lift the console cover upward to expose the shift
control lever mechanism.
5. Rotate the gearshift lever stop clamp and remove it.
6. Remove the gearshift lever from the gearshift lever
shaft.
Installation Procedure
1. Install the gearshift lever into the gearshift lever
shaft.
2. Install the gearshift lever stop clamp.
3. Rotate the gearshift lever stop clamp to secure it.
4. Lower the boot and connect it to the console cover.
5. Connect the negative battery cable.

5B – 18IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
GEARSHIFT LEVER HOUSING
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the rod clamp. Refer to ”Shift Linkage Ad-
justment” in this section.
3. Remove the console.
4. Remove the gearshift lever housing bolts and the
gearshift lever housing.
Installation Procedure
1. Install the gearshift lever housing and the gearshift
lever housing bolts.
Tighten
Tighten the gearshift housing bolts to 7 NSm ( 62 lb–
in).
2. Adjust the shift linkage.
3. Install the console.
4. Connect the negative battery cable.
SPEEDOMETER DRIVEN GEAR
Removal Procedure
1. Disconnect the speedometer speed sensor electri-
cal connector.
2. Remove the speedometer housing retaining bolt.
3. Remove the speedometer–driven gear and the
speedometer housing.