Daewoo Matiz (2003 year). Manual - part 161

FIVE-SPEED MANUAL TRANSAXLE  5B – 27

D103B712

D

Remove the counter shaft fifth–gear (4).

D103B713

14. Remove the side cover plate and the counter shaft

bearing shim.

D

Remove the screws (1).

D

Remove the side cover plate (2).

D

Remove the counter shaft bearing shim.

D103B714

15. Remove the shift shaft spring and ball.

D

Remove the bolt and remove the fifth–reverse
gear shift shaft spring and ball (1).

D

Remove the bolt and remove the third–fourth
gear shift shaft spring and ball (2).

D

Remove the bolt and remove the first–second
gear shift shaft spring and ball (3).

Important: There is difference between the fifth–re-
verse gear shift shaft spring and the others. Mark it to
distinguish easily when installing.

D103B715

16. Remove the reverse idle gear shaft bolt.

Important: The case (Left) can not be removed without
removing the reverse idle gear shaft bolt.

5B – 28  FIVE-SPEED MANUAL TRANSAXLE

D103B716

17. Remove the transaxle case (Left).

D

Remove the bolts from the left side case (1).

D

Remove the bolts, stud bolts if equipped with
auto clutch.

D

Remove the bolts from the right side of case (2).

D

Remove the left side case by hitting with a rubber
hammer lightly.

D

Remove the sealant on the case.

D103B717

18. Remove the reverse gear shift lever.

D

Remove the bolts (1).

D

Remove the reverse gear shift lever (2).

D103B718

19. Remove the reverse idle gear shaft assembly.

D

Push the reverse idle gear toward inner case.

D

Pulling shaft and remove the reverse idle gear
and shaft (1).

D

Remove the reverse idle gear from the shaft.

D103B719

20. Remove the fifth–reverse gear shift shaft.

a. Fifth–reverse gear shift shaft.

FIVE-SPEED MANUAL TRANSAXLE  5B – 29

D103B720

21. Remove the gear unit.

D

Remove the gear unit and the shift shaft assem-
bly together (1).

Notice: Be careful not to damage teeth of the counter
shaft pinion and the differential ring gear.

D

Remove the high and the low speed shift shaft
assembly from the gear unit.

D103B721

22. Remove the differential assembly.

D

Insert a wooden stick into the lower side of differ-
ential (1).

D

Remove the differential assembly by moving it
right and left (2).

D103B722

23. Remove the related parts of the transaxle case (Left

Side).

D

Remove the bolt (1).

D

Remove the oil gutter (2).

D

Remove the bolts (3).

D

Remove the oil plate (4).

D

Remove the differential left side oil seal using a
hammer and a copper chisel (5).

D103B723

D

Remove the bolts (6).

D

Remove the case cap (Left Side) (7).

D

Remove the case cap O–ring (Left Side) (8).

D

Remove the oil level plug (including steel gasket)
(9).

D

Remove the counter shaft bearing outer race us-
ing a hammer and the gear, bearing installer DW
09940–53111.

5B – 30  FIVE-SPEED MANUAL TRANSAXLE

D103B724

24. Remove the related parts of the transaxle case

(Right Side).

D

Remove the input shaft oil seal using a screwdriv-
er (1).

D

Remove the differential left side oil seal using a
hammer and a copper chisel (2).

D103B725

Synchronizer Sleeve and Shift Fork
Inspection

1. Measure the clearance between synchronizer sleeve

and shift fork and if the clearance exceeds the limit,
replace the shift fork.

Unit : mm (in.)

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

Clearance Between

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Standard

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Limit

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

Clearance Between

Sleeve and Shift

Fork

0.2 

∼

0.6

(0.008

∼

0.024)

1.0

(0.039)

D103B726

Assembly Procedure

1. Install the related parts of the transaxle case (Right

Side).

D

Install the input shaft oil seal using the bushing
seal installer DW09943–78210.

D

Install the differential right side oil seal using the
bushing, seal installer 09913–76010.

Important: Use only a new oil seal.

Important: Coat the transaxle inner parts with gear fluid
when installing.

D13B727A

2. Install the related parts of the transaxle case (Left

Side).

D

Install the oil plate with the bolts.

D

Install the oil gutter with the bolt.

D

Install the oil level plug (including steel gasket).

a. Oil level plug.

Tighten

Tighten the oil level plug to 36–54 N

S

m (26–40 lb-ft).

D

Install the left side case cap with the bolts (includ-
ing O–ring) (1).