Daewoo Nubira. Manual — part 62

4E – 18

I

REAR DISC BRAKES

DAEWOO V–121 BL4

GENERAL DESCRIPTION

AND SYSTEM OPERATION

DISC BRAKE CALIPER

The caliper has a single bore and it is mounted to a bracket
on the wheel knuckle. Hydraulic pressure, which is trans-
mitted to the piston and the caliper, is created by pressing
the brake pedal. During braking, the piston and the caliper
apply a clamping force on the brake shoes. The vehicle is
stopped as a result of the friction between the rotor and the
brake shoes.

S

When servicing a caliper, replace all parts included
in the caliper repair kit.

S

During caliper overhaul, lubricate the piston and the
inner seal with clean brake fluid to ease assembly.

S

Do not use lubricated shop air on brake parts be-
cause oil will deteriorate rubber seals.

S

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of
the brake system.

S

Replace the shoes in axle sets only.

S

The torque values specified are for dry, unlubri-
cated fasteners.

S

Perform the service operations on a clean bench
away from oily material.

SECTION : 5C

CLUTCH

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 terminals. 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

5C0–1

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

FASTENER TIGHTENING

SPECIFICATIONS

5C0–1

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

SPECIAL TOOLS

5C0–2

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

SPECIAL TOOLS TABLE

5C0–2

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

DIAGNOSIS

5C0–2

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

CLUTCH OPERATION

5C0–2

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

COMPONENT LOCATOR

5C0–4

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

HYDRAULIC CLUTCH COMPONENTS

5C0–4

. . . . .

MAINTENANCE AND REPAIR

5C0–7

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

ON–VEHICLE SERVICE

5C0–7

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

CLUTCH PEDAL

5C0–7

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

CLUTCH PEDAL POSITION SWITCH

5C0–9

. . . . . . .

CLUTCH DISC AND RELATED

COMPONENTS

5C0–10

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

CLUTCH PEDAL

ADJUSTMENT (HYDRAULIC)

5C0–15

. . . . . . . . . . .

CLUTCH RELEASE POINT

ADJUSTMENT (HYDRAULIC)

5C0–17

. . . . . . . . . . .

AIR BLEEDING

5C0–17

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

CLUTCH MASTER

CYLINDER ASSEMBLY

5C0–17

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

CLUTCH RELEASE

CYLINDER ASSEMBLY

5C0–20

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

UNIT REPAIR

5C0–21

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

CLUTCH MASTER CYLINDER

5C0–21

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

CLUTCH RELEASE CYLINDER

5C0–23

. . . . . . . . . . .

GENERAL DESCRIPTION AND

SYSTEM OPERATION

5C0–25

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

DRIVING MEMBERS

5C0–25

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

DRIVEN MEMBERS

5C0–25

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

OPERATING MEMBERS

5C0–25

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

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Application

N

S

m

Lb–Ft

Lb–In

Clutch Fork–to–Release Lever Shaft Bolt

35

26

Clutch Master Cylinder Locknuts

22

18

Clutch Pedal Nut

18

13

Pressure Plate–to–Flywheel Bolt

15

11

Release Bearing Guide Sleeve Bolts

5

45

Release Cylinder Bolts

60

44

5C0 – 2

I

CLUTCH

DAEWOO V–121 BL4

SPECIAL TOOLS

SPECIAL TOOLS TABLE

J–36547

Input Shaft Seal

Installer

J–42474

Clutch Arbor

DIAGNOSIS

CLUTCH OPERATION

Fails to Release

Checks

Action

DEFINITION: When the pedal is pressed to the floor, the shift lever does not move freely in and out of reverse gear.

Check for a loose linkage.

Repair or replace loose linkage, if necessary.

Check for a damaged clutch disc.

Replace the damaged clutch disc.

Check for an improperly installed fork shaft.

Remove and properly reinstall the fork shaft. Very lightly
lubricate the fork fingers at the release bearing with wheel
bearing grease.

Check for the clutch disc hub binding on the input shaft
splines.

Repair or replace the clutch disc hub.

Check for a warped or bent clutch disc.

Replace the warped or bent clutch disc.

Slipping

Checks

Action

Check for the driver improperly operating the vehicle.

Correct the driver’s operation of the vehicle as necessary.

Check for an oil–soaked clutch disc.

Correct the leak at its source and install a new clutch disc.

Check for a worn facing or a facing torn from the disc.

Replace the worn disc with a new disc.

Check for a warped pressure plate or a warped flywheel.

Replace the warped pressure plate or the warped fly-
wheel.

Check for a weak diaphragm spring.

Replace the pressure plate.

Check for a driven plate that is not seated.

Start the engine 30 to 40 times. Do not overheat the en-
gine.

Check for a driven plate that is overheated.

Allow the driven plate to cool.

CLUTCH 5C0 – 3

DAEWOO V–121 BL4

Grabbing (Chattering)

Checks

Action

Check for a burned or a glazed facing caused by oil on the
facing.

Correct the leak at its source and install a new clutch disc.

Check for worn splines on the input shaft.

Replace the worn input shaft.

Check for a warped pressure plate or a warped flywheel.

Replace the warped pressure plate or the warped fly-
wheel.

Check for burned or smeared resin on the flywheel or the
pressure plate.

Sand off the burned or smeared resin if it is superficial.
Replace any burned or heat–checked parts.

Rattling (Transaxle Click)

Checks

Action

Check for weak retracting springs.

Replace the pressure plate.

Check for a loose release fork.

Remove and reinstall the release fork properly.

Check for oil in the driven plate damper.

Correct the cause of the oil leak and replace the driven
disc.

Check for a damaged driven plate damper spring.

Replace the driven disc.

Release Bearing Noise with Clutch Fully Engaged

Checks

Action

Check for the driver improperly operating the vehicle.

Correct the driver’s operation of the vehicle as necessary.

Check for a binding release bearing.

Clean and re–lubricate the release bearing. Inspect the re-
lease bearing for burrs and nicks.

Check for an improperly installed release lever.

Remove and reinstall the release lever properly.

Check for a weak linkage return spring.

Replace the weak linkage return spring.

Noisy

Checks

Action

Check for a worn release bearing.

Replace the worn release bearing.

Check for an improperly installed release lever.

Remove and properly reinstall the fork shaft. Very lightly
lubricate the fork fingers at the release bearing with wheel
bearing grease.

Pedal Stays on Floor When Disengaged

Checks

Action

Check for binding in the linkage or the release bearing.

Lubricate and free–up the binding linkage or the release
bearing.

Check for weak pressure plate springs.

Replace the pressure plate.

Hard Pedal Effort

Checks

Action

Check for binding in the linkage.

Lubricate and free–up the binding linkage.

Check for a worn driven plate.

Replace the worn driven plate.