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)
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