2004 DAEWOO NUBIRA brake sensor

5A1 – 48IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
The Lock up clutch should not apply unless the transaxle
has reached a minimum operating temperature of 8°C
(46°F) TRANS TEMP AND engine coolant temp of 50°C
(122°F).
5. Repeat steps 1–4 using several different throttle
angles.
Part Throttle Detent Downshift
At vehicle steeds of 55 to 65km/h (34 to 40mph) in Fourth
gear, quickly increase throttle angle to greater than 50%.
Verify that :
S TCC apply.
S Transaxle downshift to 3rd gear.
S Solenoid 1 turns ON to OFF.
S Solenoid 2 turns OFF.
Full Throttle Detent Downshift
At vehicle speeds of 55 to 65km/h (34 to 40mph)in Fourth
gear, quickly increase throttle angle to its maximum posi-
tion (100%)
Verify that :
S TCC release.
S Transaxle downshift to Second gear immediately.
S Solenoid 1 turns ON to OFF
S Solenoid 2 turns OFF.
Manual Downshifts
1. At vehicle speeds of 60km/h (40mph)in Fourth
gear, release accelerator pedal while moving gear
selector to Manual Third (3). Observe that :
S Transaxle downshift to Third gear immediately.
S Engine slows vehicle down.
2. Move gear selector back to overdrive(D) and accel-
erate to 31mph (50km/h). Release the accelerator
pedal and move the gear selector to Manual
First(1) and observe that :
S Transaxle downshift to second gear immediate-
ly.
S Engine slows vehicle down
Notice : A Manual First––Third Gear Ratio will occur at
high speeds as an upshift safety feature. Do not attempt
to perform this shift.
Coasting Downshifts
1. With the gear selector in Overdrive(D), accelerate
to Fourth gear with TCC applied.
2. Release the accelerator pedal and lightly apply the
brakes, and observe that :
S TCC release.
S Down shifts occur at speeds shown ON the shift
speed chart.
Manual Gear Range Selection
Upshifts in the manual gear ranges are controlled by the
shift solenoids. Perform the following tests by accelerating
at 25 percent TP sensor increments.
Manual Third (3)
S With vehicle stopped, move the gear selector to
Manual third(3) and accelerate to observe :
– 1–2 shift.
– 2–3 shift.
Manual Second (2)
S With vehicle stopped, move the gear selector to
Manual second(2) and accelerate to observe :
– 1–2 shift.
S Accelerate to 40km/h(25mph) and observe :
– 2–3 shift does not occur
– TCC does not apply
Manual First (1)
S With vehicle stopped, move gear selector to Manu-
al First(1). Accelerate to 30km/h(19mph) and ob-
serve :
– No upshifts occur
Reverse (R)
S With vehicle stopped, move gear selector to R(Re-
verse) and observe :
– Solenoid 1 is OFF
– Solenoid 2 is OFF
Use a scan tool to see if any transaxle trouble codes have
been set. Refer to ”Diagnostic Trouble Codes”in this sec-
tion and repair the vehicle as directed. After repairing the
vehicle, perform the hoist test and verify that the code has
not set again.
If the transaxle is not performing well and no trouble codes
have been set, there may be an intermittent condition.
Check all electrical connections for damage or a loose fit.
You also have to perform a snapshot test which can help
catch an intermittent condition that dose not occur long
enough to set a code.
You may want to read ”Electronic Component Diagnosis”
in this section to become familiar with transaxle conditions
caused by transaxle electrical malfunction.
If no trouble codes have been set and the condition is sus-
pected to be hydraulic, take the vehicle on a road test.
TORQUE CONVERTER LOCK–UP
CLUTCH(TCC) DIAGNOSIS
To properly diagnosis the lock–up clutch(TCC) system,
perform all electrical testing first and then the hydraulic
testing.
The TCC is applied by fluid pressure which is controlled by
a solenoid Located inside the valve body. The solenoid is
energized by completing an electrical circuit through a
combination of switches and sensors.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 57
DAEWOO V–121 BL4
Symptom ActionPossible Cause
Sealing Ring Selector ShaftS Check sealing ring.
S Replace sealing ring as described in the repair
instruction.
O–ring at Socket OutletS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
O–ring and Speed Sensor ConnectionS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
Oil Leak Incorrectly IdentifiedS No oil leak is possible at this point.
Speed Sensor Itself Is LeakingS Check speed sensor.
S Replace speed sensor as described in the re-
pair instruction.
Hair Line Crack at the Piping in the Con-
nection Area, Sealing Ring Fit in Trans-
axle HousingS Pressurize the line with compressed air and
check it.
S Replace lines as described in the repair in-
struction.
O–ring Defective, IncorrectCheck O–ring.
Replace O–rings as described in the repair instruc-
tion.
Plug LooseCheck the Tightening Torque for the screw plug.
Tighten to torque specified in the repair instruction.
Noise
SymptomPossible CauseAction
NoiseTFT Level Too LowS When the TFT level is too low, the gear wheels
from the transaxle oil pump might generate
noise.
S Check the TFT level as described in the repair
instruction and fill to the proper level.
Monolith in Catalytic Converter Has
BrokenS Check according to the exhaust gas diagnostic
procedure or by shaking the catalytic converter
casing.
S Replace catalytic converter if necessary.
Noise from Auxiliaries (e.g. exhaust
system, alternator, drive shafts.)S Check these components; if necessary, elimi-
nate the faults as described in the repair in-
struction
Noise from Tires or Wheel BearingsS Eliminate fault if necessary
Noise from Planetary GearsS Whistling noise on traction and overrun(in first
gear only)caused by high rotating speeds(func-
tionally unavoidable)
Cumulative Tooth Backlash in the Com-
plete Drive LineS Production status. Customer must be con-
vinced.
Jerky Noise of the Parking Lock (e.g.
when the car is standing on a gradient)S Load–reversal reaction
S Apply the handbrake before selection the park-
ing Lock (position P)

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 61
DAEWOO V–121 BL4
DTCDefault Action Indication Description
P0703Brake Switch Circuit
MalfunctionNo ChangeS TCM assume that the brake light always active.
S Open lock up clutch.
P0705Transmission Range Sen-
sor Circuit Malfunction
(PRNDL Input)MIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control,
position P, R and N also possible.
P0710S Transmission Fluid
Temperature Sensor
Circuit MalfunctionNo ChangeS TCM assume the transaxle fluid temperature is
140°F (60°C).
S No influence at vehicle running.
P0715S Input Speed Sensor
Circuit MalfunctionMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control,
position P, R and N also possible.
S Open lock up clutch.
P0716S Input Speed Sensor
Circuit Range/Perfor-
manceMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control,
position P, R and N also possible.
S Open lock up clutch.
P0717S Input Speed Sensor
Circuit Range/Perfor-
manceMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control,
position P, R and N also possible.
S Open lock up clutch.
P0720Output Speed Sensor Cir-
cuit MalfunctionMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear.
S Open lock up clutch.
P0721Output Speed Sensor Cir-
cuit Range/PerformanceMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear.
S Open lock up clutch.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 87
DAEWOO V–121 BL4
Gear Position And Range Signal Chart.
L1L2L3L4
P00120
R00012
N01200
D1212120
31212012
21201212
10121212
DTC P0705 – Transmission Range Sensor Circuit Malfunction
(PRNDL Input)
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON.
3. Record then clear DTC(s) and turn the ignition
OFF, then turn the ignition ON.
4. Applying the brakes and select each transaxle
range (P, R,N,D,3,2,1), while monitoring scan
tool.
Refer to Gear Position And Range Signal Chart.
Does each selected transaxle range match scan tool
and signal range chart?–Go to Step 3Go to ”Diag-
nostic Aids”
3Inspect the F2 for open?
Was a problem found?–Go to Step 4Go to Step 5
4Replace the fuse as necessary.
Is the action complete?–System OK–
5Inspect the TR switch. Refer to ”Diagnostic Aids”.
Was the problem found?–Go to Step 6Go to Step 7
6Replace the TR switch.
Is the action complete?–System OK–
71. Disconnect the TR switch connector and TCM
connector.
2. Measure the resistance between terminal 3 of
the TR switch and terminal C1 of the TCM con-
nector.
3. Measure the resistance between terminal 2 of
the TR switch and terminal B15 of the TCM
connector.
4. Measure the resistance between terminal 4 of
the TR switch and terminal B6 of the TCM con-
nector.
5. Measure the resistance between terminal 5 of
the TR switch and terminal B11 of the TCM
connector.
Is the resistance within the values shown?0ΩGo to Step 9Go to Step 8

5A1 – 116IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
DIAGNOSTIC TROUBLE CODE(DTC) P0731
GEAR 1 INCORRECT RATIO
Circuit Description
The TCM uses transaxle input speed information and out-
put speed sensor to control line pressure, TCC apply and
release and transaxle shift patterns. This information is
also uses to calculate the appropriate operating gear ra-
tios and TCC slippage. Conditions for Setting the DTC.
Conditions for Setting The DTC
S Time since TCM reset is greater than 500 msec.
S Time since shift end is greater than 500 msec.S Transmission oil temperature is greater than –10°C
(14°F).
S System voltage is greater than 9 volts.
S No input speed error DTCs P0715, P0716, and
P0717.
S Output speed is greater than 256 rpm.
S Input speed is greater than 400 rpm.
S No gear shift active.
Action Taken When The DTC Sets
S The Malfunction Indicator Lamp(MIL) will illuminate.

5A1 – 118IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
DIAGNOSTIC TROUBLE CODE(DTC) P0732
GEAR 2 INCORRECT RATIO
Circuit Description
The TCM uses transaxle input speed information and out-
put speed sensor to control line pressure, TCC apply and
release and transaxle shift patterns. This information is
also uses to calculate the appropriate operating gear ra-
tios and TCC slippage. Conditions for Setting the DTC.
Conditions for Setting The DTC
S Time since TCM reset is greater than 500 msec.
S Time since shift end is greater than 500 msec.S Transmission oil temperature is greater than –10°C
(14°F).
S System voltage is greater than 9 volts.
S No input speed error DTCs P0715, P0716 or
P0717.
S Output speed is greater than 256 rpm.
S Input speed is greater than 400 rpm.
S No gear shift active.
Action Taken When The DTC Sets
S The Malfunction Indicator Lamp(MIL) will illuminate.

5A1 – 120IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
DIAGNOSTIC TROUBLE CODE(DTC) P0733
GEAR 3 INCORRECT RATIO
Circuit Description
The TCM uses transaxle input speed information and out-
put speed sensor to control line pressure, TCC apply and
release and transaxle shift patterns. This information is
also uses to calculate the appropriate operating gear ra-
tios and TCC slippage. Conditions for Setting the DTC.
Conditions for Setting The DTC
S Time since TCM reset is greater than 500 msec.
S Time since shift end is greater than 500 msec.S Transmission oil temperature is greater than –10°C
(14°F).
S System voltage is greater than 9 volts.
S No input speed error DTCs P0715, P0716, and
P0717.
S Output speed is greater than 256 rpm.
S Input speed is greater than 400 rpm.
S No gear shift active.
Action Taken When The DTC Sets
S The Malfunction Indicator Lamp(MIL) will illuminate.

5A1 – 122IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
DIAGNOSTIC TROUBLE CODE(DTC) P0734
GEAR 4 INCORRECT RATIO
Circuit Description
The TCM uses transaxle input speed information and out-
put speed sensor to control line pressure, TCC apply and
release and transaxle shift patterns. This information is
also uses to calculate the appropriate operating gear ra-
tios and TCC slippage. Conditions for Setting the DTC.
Conditions for Setting The DTC
S Time since TCM reset is greater than 500 msec.
S Time since shift end is greater than 500 msec.S Transmission oil temperature is greater than –10°C
(14°F).
S System voltage is greater than 9 volts.
S No input speed error DTCs P0715, P0716, and
P0717.
S Output speed is greater than 256 rpm.
S Input speed is greater than 400 rpm.
S No gear shift active.
Action Taken When The DTC Sets
S The Malfunction Indicator Lamp(MIL) will illuminate.