Daewoo Matiz (2003 year). Manual - part 165

FIVE-SPEED MANUAL TRANSAXLE 5B – 43

D103B769

Remove the counter shaft first–second gear syn-
chronizer hub assembly, the first gear / the first gear
synchronizer ring.

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

Remove the following parts by pressing.

a. Synchronizer hub assembly.

b. First gear / First gear synchronizer ring.

Remove the first gear synchronizer ring from the
first gear.

D103B770

10. Disassemble the first–second gear synchronizer

hub assembly.

Push the hub from the hub assembly (1).

Disassemble the synchronizer sleeve and key
(2).

Disassemble the synchronizer springs (3).

D103B771

11. Remove the counter shaft first gear bearing.

D103B772

Synchronizer Hub and Sleeve Inspection

Check the sleeve for improper operation after assem-
bling the hub and the sleeve.

Check the wear of hub and sleeve.

Replace synchronizer hub or sleeve if necessary.

5B – 44 FIVE-SPEED MANUAL TRANSAXLE

D103B773

Assembly Procedure

1. Install the related counter shaft first gear.

Install the first gear bearing (1).

Install the first gear (2).

Install the first gear synchronizer ring (3)

Important: Coat the inner parts; gear, bearing and oil
seal etc. with gear fluid.

Important: Be careful there is the difference of key
groove width between the first synchronizer ring and the
second synchronizer ring.

D103B774A

Unit : mm (in.)

ÁÁÁÁÁÁÁÁÁ

First synchronizer ring (A)

: 8.2 (0.323)

ÁÁÁÁÁÁÁÁÁ

Key Groove Width

ÁÁÁÁÁÁÁÁÁ

Second synchronizer ring

(B) : 9.6 (0.378)

D103B775

2. Assemble the first–second synchronizer hub assem-

bly.

Install the synchronizer springs to hub.

Install the synchronizer keys to hub.

Important: Let (A)=(B) when installing the keys.

Install the hub to the sleeve.

a. Sleeve.

b. Hub.

D103B776

3. Install the first–second synchronizer hub assembly.

Insert the hub assembly into the counter shaft us-
ing the gear, bearing installer DW09940–53111,
the gear bearing remover/installer KM466–A and a
hammer (1).

Important: Position the synchronizer key to the first
gear synchronizer ring groove.

FIVE-SPEED MANUAL TRANSAXLE 5B – 45

D103B768

4. Install the second synchronizer ring.

Important: Position the second synchronizer ring groove
to the synchronizer hub key.

5. Install the first–second gear synchronizer circlip.

D103B777

6. Install the related counter shaft second gear.

Install the second gear bearing (1).

Install the second gear (2).

D103B778

7. Install the counter shaft third gear and the third–fourth

gear spacer.

Insert the third gear and the third–fourth gear
spacer into the counter shaft.

Install the following parts using the gear, bearing
installer DW09913–80112 and a hammer.

a. Third–fourth gear spacer.

b. Third gear.

D103B779

8. Install the counter shaft fourth gear.

Install the fourth gear to the counter shaft using the
gear, bearing installer DW09925–98221 and a
hammer (1).

5B – 46 FIVE-SPEED MANUAL TRANSAXLE

D103B780

Install the counter shaft left side bearing.

Install the left side bearing to the counter shaft us-
ing the gear, bearing installer DW09925–98221
and a hammer (1).

D103B765

10. Install the counter shaft right side bearing.

11. Install the gear unit. Refer to “Gear Unit” in this sec-

tion.

D103B781

GEAR SHIFT FORK

Disassembly Procedure

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

section.

2. Remove the each shift shaft assembly from the gear

unit.

3. Remove the first–second gear shift shaft assembly.

Fix the shift shaft assembly to a vise with protector.

Remove the first–second gear fork pin using a pin
punch and a hammer (1).

Remove the first–second gear shift fork (2).

D103B783

Remove the first–second gear shift yoke pin using
a pin punch and a hammer (3).

Remove the first–second gear shift yoke (4).

Important: Mark the place and direction of shift fork and
yoke to install easily before removing them.

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