Daewoo Matiz (2003 year). Manual - part 160

FIVE-SPEED MANUAL TRANSAXLE  5B – 23

D13B544A

Installation Procedure

1. Install in the reverse order of removal.

2. Install the gear shift control lever assembly.

Tighten

Tighten the bolts to 4–7 N

S

m (35–62 lb-in).

3. Adjust the select cables. Refer to “Gear Shift Control

Cable” in this section.

5B – 24  FIVE-SPEED MANUAL TRANSAXLE

MAINTENANCE AND REPAIR

UNIT REPAIR

D13B701A

GEAR UNIT

Tools Required

09913–76010

Bushing, Seal Installer

DW09940–53111

Gear, Bearing Installer

DW09943–78210

Bushing, Seal Installer

DW220–010A

Transaxle Fixture

KM519

Oil Seal Installer

Disassembly Procedure

1. Remove the manual transaxle. Refer to “Manual

Transaxle Assembly” in this section.

2. Position the manual transaxle to a transaxle stand us-

ing the transaxle fixture DW220–010.

D13B7021

3. Remove the related clutch parts. Refer to Section 5C,

Clutch.

4. Remove the manual transaxle mounting bracket.

D

Remove the bolts (1).

D

Remove the nut (2).

D

Remove the mounting bracket (3).

D103B703

5. Disconnect the backup light switch and speedometer

driven gear assembly.

D

Remove the nut (1).

D

Disconnect the backup light switch (2).

D

Remove the bolt (3).

D

Remove the speedometer driven gear assembly
(4).

FIVE-SPEED MANUAL TRANSAXLE  5B – 25

D103B704

6. Remove the select lever.

D

Remove the bolt (1).

D

Remove the select lever (2).

D103B705

7. Remove the gear shift control case assembly.

D

Remove the bolts (1).

D

Remove the shift interlock bolt (2).

Important: Certainly remove the shift interlock bolt.
Otherwise, gear shift control case can not be removed.

D

Remove the gear shift control case assembly (3).

D

Remove the gasket (4).

D103B706

8. Remove the side cover.

D

Remove the bolts (1).

D

Remove the side cover using a rubber hammer (2).

D

Remove the sealant on the side cover and the
transaxle case.

D103B707

9. Remove the fifth–gear shift fork guide ball, the snap

ring and the input shaft fifth–gear snap ring.

D

Remove the fifth–gear shift fork plug (1).

D

Remove the guide ball using a magnet.

D

Remove the fifth–gear shift fork snap ring (2).

D

Remove the fifth–gear snap ring (3).

D

Remove the fifth–gear synchronizer plate.

5B – 26  FIVE-SPEED MANUAL TRANSAXLE

D103B708

10. Remove the fifth–gear shift fork pin.

D

Shift the shift fork to the fifth–gear.

D

Remove the fork pin using a pin punch and a
hammer (1).

D103B709

11. Remove the input shaft fifth–gear fork and synchro-

nizer hub assembly.

D

Pull and remove the fork and the hub assembly
together (1).

D

Remove the sleeve, key and spring from the syn-
chronizer hub assembly.

D103B710

12. Remove the input shaft fifth–gear, the synchronizer

ring and the fifth–gear bearing.

D

Pull and remove the fifth–gear, wave spring and
synchronizer ring together (1).

D

Remove the fifth–gear bearing.

D103B711

13. Remove the countershaft fifth–gear.

D

Shift the shift yoke using a driver to engage the
first–gear and the third–gear or the second–gear
and the fourth–gear (1).

D

Remove the caulking and the nut. (2, 3)