Daewoo Matiz (2003 year). Manual - part 163

FIVE-SPEED MANUAL TRANSAXLE  5B – 35

D103B740

20. Install the fifth gear shift fork pin.

D

Push the shift fork toward the fifth gear.

D

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

Important: Use only new shift fork pin.

D103B741

21. Install the input shaft fifth gear snap ring, the fifth

gear shift fork snap ring and guide ball.

D

Install the fifth gear synchronizer plate.

D

Install the fifth gear snap ring (1).

D

Install the fork snap ring (2).

Important: Use only new snap ring.

D

Tighten the fork plug after inserting the guide ball
into the fork hole.

D13B742A

22. Install the side cover(1).

D

Coat the side cover with recommended sealant.

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

Side Cover Sealant

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

THREE BOND 1215

Tighten

Tighten the side cover bolts to 8–12 N

S

m (71–106

lb-in).

D13B743A

23. Install the gear shift control case assembly.

D

Install the case gasket.

D

Install the gear shift control case.

Tighten

D

Tighten the bolts to 18–28 N

S

m (13–21 lb-ft) (a).

D

Tighten the shift interlock bolt to 18–28 N

S

m (13–

21 lb-ft) (b).

D

Install the select lever.

Tighten

Tighten the bolts to 18–28 N

S

m (13–21 lb-ft) (c).

5B – 36  FIVE-SPEED MANUAL TRANSAXLE

D13B744A

24. Install the backup light switch and the speedometer

driven gear assembly.

D

Install the backup light switch (1).

Tighten

Tighten the nut to 15–18 N

S

m (11–13 lb-ft) (a).

D

Install the speedometer driven gear assembly
(2).

Tighten

Tighten the bolt to 4–7 N

S

m (35–62 lb-in) (b).

D

Install the hydraulic pump assembly (If equipped
with auto clutch). Refer to Section 5D, Auto
Clutch.

D13B7452

25. Install the transaxle mount.

D

Install the mount (1).

Tighten

D

Tighten the bolts to 55–65 N

S

m (41–48 lb-ft) (a).

D

Tighten the nut to 55–65 N

S

m (41–48 lb-ft) (b).

D13B701A

26. Install the related clutch parts. Refer to Section 5C,

Clutch.

27. Remove the transaxle assembly from transaxle

stand.

D

Remove the transaxle assembly using the trans-
axle fixture DW220–010A.

28. Install the transaxle assembly. Refer to “Manual

Transaxle Assembly” in this section.

D103B746

INPUT SHAFT

Tools Required

DW09921–57810 Gear, Bearing Remover
DW09925–98221 Gear, Bearing Installer
DW09940–53111 Gear, Bearing Installer

Disassembly Procedure

1. Remove the gear unit. Refer to “Gear Unit” in this

section.

2. Remove the input shaft right side bearing.

D

Position the bearing to the gear, bearing remover
DW09921–57810.

D

Remove the bearing by pressing (1).

FIVE-SPEED MANUAL TRANSAXLE  5B – 37

D103B747

3. Remove the input shaft fifth gear spacer, the left side

bearing and the fourth gear.

D

Position the fourth gear to the gear,bearing remov-
er DW09921–57810.

D

Remove the following parts.

a. Fifth gear spacer.

b. Left side bearing.

c. Fourth gear

D103B748

4. Remove the fourth gear bearing.

5. Remove the fourth gear synchronizer ring and wave

spring.

D103B749

6. Remove the third–fourth synchronizer circlip.

D103B750

7. Remove the third–fourth synchronizer hub assembly,

the third gear 1 synchronizer ring.

D

Position the third gear to the gear, bearing remover
DW09921–57810.

D

Remove the following parts.

a. Third–fourth synchronizer hub assembly.

b. Third gear and synchronizer ring.

5B – 38  FIVE-SPEED MANUAL TRANSAXLE

D103B751

8. Disassemble the third–fourth synchronizer hub as-

sembly.

D

Remove the hub (1).

D

Remove the synchronizer sleeve and the key (2).

D

Remove the synchronizer springs (3).

D103B752

9. Remove the input shaft third gear bearing (1).

D103B753

Synchronizer Assembly Inspection

1. Inspecting wear of cone area.

D

After matching synchronizer ring to gear, measure
as shown in figure. Replace if it is below limit.

Unit : mm (in.)

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

Clearance Between

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Standard

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Limit

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

Clearance Between

Gear and Ring

1.0 (0.039)

0.5 (0.020)

D103B754

2. Inspecting cone contact condition.

D

When synchronizer mechanism is abnormal in op-
eration, connection between ring inner surface and
gear cone area is considered to be partially defec-
tive in spite of correct clearance between gear and
ring. Therefore, cone area and ring inner surface
shall be inspected. In this case, ring inner surface
shall be glossy. Black area is abnormal and if in-
spection is difficult, check after applying red lead.
Cone area can be worn in wave form.