Daewoo Nubira. Manual - part 163

AUTOMATIC TRANSAXLE DRIVE AXLE  3A – 11

DAEWOO V–121 BL4

8.  Remove the tripot and the tripot joint retaining ring

from the axle shaft.

9.  Remove the tripot joint seal from the axle shaft.

Installation Procedure

Tools Required
J–35566 Seal Clamp Pliers
1.  Install a new small seal retaining clamp onto the

seal. Do not crimp the seal retaining clamp.

2.  Install the seal onto the axle shaft.
3.  Install the tripot joint retaining ring and the tripot

onto the axle shaft.

4.  Install the shaft retaining ring onto the axle shaft

using the snap ring pliers J–8059.

3A – 12

I

AUTOMATIC TRANSAXLE DRIVE AXLE

DAEWOO V–121 BL4

5.  Fill the tripot housing with 195 to 215 g (6.9 to 7.6

ounces) of the recommended grease. Repack the
tripot with 195 to 215 g (6.9 to 7.6 ounces) of the
recommended grease.

6.  Install the tripot housing onto the tripot assembly.

7.  Install the tripot joint retaining ring into the tripot

housing.

8.  Install a new large seal retaining clamp. Crimp the

large seal retaining clamp using the seal clamp pli-
ers J–35566.

9.  Crimp the new small seal retaining clamp using the

seal clamp pliers J–35566.

10.  Install the drive axle shaft to the vehicle. Refer

to”Drive Axle Assembly” in this section.

AUTOMATIC TRANSAXLE DRIVE AXLE  3A – 13

DAEWOO V–121 BL4

GENERAL DESCRIPTION

AND SYSTEM OPERATION

FRONT DRIVE AXLE

General Description

Drive axles are flexible shaft assemblies that transmit
rotational force from the transaxle to the front–wheel as-
semblies. Each axle assembly consists of an inner and an

outer constant–velocity joint connected to an axle shaft.
The inner joint is completely flexible and has the ability to
move in and out. The outer joint is also flexible, but it can-
not move in and out.

The drive axles use one type of outboard joint and one type
of inboard joint. The inboard ends of both drive axles incor-
porate a female spline that installs over a stub shaft pro-
truding from the transaxle.

SECTION : 5A

4T40–E AUTOMATIC TRANSAXLE

CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

TABLE OF CONTENTS

SPECIFICATIONS

5A–6

. . . . . . . . . . . . . . . . . . . . . . . . . . 

END PLAY SPECIFICATIONS

5A–6

. . . . . . . . . . . . . . 

TRANSAXLE GENERAL 

SPECIFICATIONS

5A–6

. . . . . . . . . . . . . . . . . . . . . . . 

FLUID CAPACITY

5A–6

. . . . . . . . . . . . . . . . . . . . . . . . . 

RANGE REFERENCE

5A–7

. . . . . . . . . . . . . . . . . . . . . 

4T40–E GEAR RATIOS

5A–8

. . . . . . . . . . . . . . . . . . . . 

SHIFT SPEED

5A–8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

LINE PRESSURE

5A–8

. . . . . . . . . . . . . . . . . . . . . . . . . 

FASTENER TIGHTENING 

SPECIFICATIONS

5A–8

. . . . . . . . . . . . . . . . . . . . . . . 

SPECIAL TOOLS

5A–10

. . . . . . . . . . . . . . . . . . . . . . . . . . 

SPECIAL TOOLS TABLE

5A–10

. . . . . . . . . . . . . . . . . . 

SCHEMATIC AND ROUTING DIAGRAMS

5A–15

. . . . 

POWERTRAIN CONTROL 

MODULE (1 OF 3)

5A–15

. . . . . . . . . . . . . . . . . . . . . . 

POWERTRAIN CONTROL 

MODULE (2 OF 3)

5A–16

. . . . . . . . . . . . . . . . . . . . . . 

POWERTRAIN CONTROL 

MODULE (3 OF 3)

5A–17

. . . . . . . . . . . . . . . . . . . . . . 

VISUAL IDENTIFICATION

5A–18

. . . . . . . . . . . . . . . . . . 

TRANSAXLE IDENTIFICATION 

INFORMATION

5A–18

. . . . . . . . . . . . . . . . . . . . . . . . . 

COMPONENT LOCATOR

5A–19

. . . . . . . . . . . . . . . . . . . 

OIL PUMP ASSEMBLY

5A–19

. . . . . . . . . . . . . . . . . . . . 

CONTROL VALVE BODY ASSEMBLY

5A–20

. . . . . . 

DRIVEN SPROCKET SUPPORT 

ASSEMBLY/2ND CLUTCH

5A–21

. . . . . . . . . . . . . . . 

REVERSE INPUT CLUTCH ASSEMBLY

5A–22

. . . . 

DIRECT AND COAST CLUTCH 

ASSEMBLIES

5A–23

. . . . . . . . . . . . . . . . . . . . . . . . . . 

REACTION CARRIER ASSEMBLY

5A–24

. . . . . . . . . 

INPUT CARRIER ASSEMBLY

5A–25

. . . . . . . . . . . . . . 

INPUT INTERNAL GEAR AND 

FORWARD CLUTCH HUB

5A–26

. . . . . . . . . . . . . . . 

FORWARD CLUTCH ASSEMBLY

5A–27

. . . . . . . . . . 

FORWARD CLUTCH SUPPORT 

ASSEMBLY

5A–28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

FINAL DRIVE AND DIFFERENTIAL 

ASSEMBLY

5A–29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

MANUAL SHAFT, PARKING PANEL AND

ACTUATOR ASSEMBLY

5A–30

. . . . . . . . . . . . . . . . . 

CASE AND ASSOCIATED PARTS (1 OF 3)

5A–31

. . 

CASE AND ASSOCIATED PARTS (2 OF 3)

5A–32

. . 

CASE AND ASSOCIATED PARTS (3 OF 3)

5A–34

. . 

VALVE BODY–TO–SPACER 

PLATE GASKET

5A–36

. . . . . . . . . . . . . . . . . . . . . . . . 

CHANNEL PLATE PASSAGES – 

CASE SIDE

5A–37

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

CASE PASSAGES – 

CHANNEL PLATE SIDE

5A–38

. . . . . . . . . . . . . . . . . 

CASE PASSAGES – BOTTOM

5A–39

. . . . . . . . . . . . . 

SPACER PLATE–TO–CHANNEL 

PLATE GASKET

5A–40

. . . . . . . . . . . . . . . . . . . . . . . . 

CHANNEL PLATE–TO–CASE GASKET

5A–41

. . . . . 

SPACER PLATE

5A–42

. . . . . . . . . . . . . . . . . . . . . . . . . . 

PUMP BODY OIL CHANNELS

5A–43

. . . . . . . . . . . . . 

4T40–E LEAK INSPECTION POINTS

5A–44

. . . . . . . 

ELECTRONIC COMPONENT 

LOCATION VIEWS

5A–45

. . . . . . . . . . . . . . . . . . . . . 

CONTROL VALVE BODY CHANNELS – 

CHANNEL PLATE SIDE

5A–46

. . . . . . . . . . . . . . . . . 

CONTROL VALVE BODY CHANNELS – 

OIL PUMP SIDE

5A–47

. . . . . . . . . . . . . . . . . . . . . . . . 

CHANNEL PLATE PASSAGES – 

CONTROL VALVE BODY SIDE

5A–48

. . . . . . . . . . . 

DIAGNOSIS

5A–49

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

BASIC KNOWLEDGE REQUIRED

5A–49

. . . . . . . . . . 

FUNCTIONAL CHECK PROCEDURE

5A–49

. . . . . . . 

4T40–E TRANSAXLE FUNCTIONAL 

CHECK PROCEDURE

5A–49

. . . . . . . . . . . . . . . . . . 

LINE PRESSURE CHECK PROCEDURE

5A–50

. . . . 

COMPONENT RESISTANCE 

CHECK PROCEDURE

5A–51

. . . . . . . . . . . . . . . . . .