Daewoo Matiz (2003 year). Manual - part 166

FIVE-SPEED MANUAL TRANSAXLE  5B – 47

D103B782

4. Disassemble the third–fourth gear shift shaft assem-

bly.

D

Fix the third–fourth gear shift shaft assembly to a
vise with protector.

D

Remove the third–fourth gear fork pin using a pin
punch and a hammer (1).

D

Remove the third–fourth gear fork (2).

D

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

D

Remove the third–fourth gear shift yoke (4).

D103B784

5. Disassemble the fifth–reverse gear shift shaft assem-

bly.

D

Remove the shift shaft not installed with yoke by
pushing (1).

D

Remove the following parts from the reverse shift
arm.

a. Fifth–reverse gear ball.

b. Reverse shift guide ball and spring.

D

Fix the shift shaft assembly to a vise with protector.

D

Remove the reverse gear shift arm pin using a pin
punch and a hammer (2).

D

Remove the reverse gear shift arm (3).

D103B785

D

Remove the fifth gear shift yoke pin using a pin
punch and a hammer (4).

D

Remove the fifth gear shift yoke (5).

D103B786

Inspection Procedure – Shift Shaft

1. Check for bent, deformed or damaged shift shaft.

2. Replace shift shaft if necessary.

5B – 48  FIVE-SPEED MANUAL TRANSAXLE

D103B787

Inspection Procedure – Shift Fork

1. Measure the end thickness of shift fork and replace if

below limit.

Unit : mm (in.)

ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

Shift fork end

thickness (mm)

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Standard

ÁÁÁÁÁ

ÁÁÁÁÁ

ÁÁÁÁÁ

Limit

ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

Low Speed Shift Fork

8.7 (0.343)

8.1 (0.319)

ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

High Speed Shift Fork

7.8 (0.307)

7.2 (0.283)

ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

Fifth Gear Shift Fork

7.8 (0.307)

7.2 (0.283)

D103B788

Low Speed
Shift Shaft

High Speed
Shift Shaft

5th/Reverse
Shift Shaft

Assembly Procedure

1. Install in the reverse order of removal.

Important: Use only new fork fin and yoke pin.

D103B789

DIFFERENTIAL

Disassembly Procedure

1. Remove the differential assembly. Refer to “Gear

Unit” in this section.

2. Remove the differential ring gear.

D

Fix the differential assembly to a vise with protec-
tor.

D

Remove the bolts (1).

D

Remove the ring gear (2).

D103B790

3. Remove the pinion gear pin.

D

Remove the pin using a pin punch and a hammer
(1).

FIVE-SPEED MANUAL TRANSAXLE  5B – 49

D103B791

4. Remove the pinion gear shaft.

D

Remove the shaft from the case (1).

D103B792

5. Remove the pinion gears and the side gears.

D

Remove the pinion gears and the washers (1).

Important: Remove the pinion gear and the washer by
rotating the side gear.

D

Remove the side gears (2).

D

Remove the adjust shims from the side gears (3).

D13B793A

6. Remove the differential right side bearing and

speedometer drive gear.

D

Remove the right side bearing using the differential
bearing puller DW220–020A–01 and the differen-
tial bearing plate adapter DW220–020A–02.

D

Remove the speedometer drive gear (1).

D13B794A

7. Remove the differential left side bearing.

D

Remove the left side bearing using the differential
bearing puller DW220–020A–01 and the differen-
tial bearing plate adapter DW220–020A–03.

5B – 50  FIVE-SPEED MANUAL TRANSAXLE

D103B795

Side Gear Play Inspection

1. Measure the axle direction play of side gear and re-

place a side gear washer if it exceeds limit.

UNIT : mm (in.)

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

Thrust Free Play of

Differential Side

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

0.05–0.33

(0.0020–0.0130)

UNIT : mm (in.)

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

0.90 (0.0354) 0.95 (0.0374)

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

Thrust Adjusting

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

1.00 (0.0394) 1.05 (0.0413)

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

Thrust Adjusting

Shim

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

1.10 (0.0433) 1.15 (0.0453)

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

1.20 (0.0472)

D103B796

2. After checking for worn or scratched thrust adjusting

shim, replace it if necessary.

a. Side gear.

b. Driver.

D103B797

Assembly Procedure

1. Install the differential left side bearing.

D

Insert the left side bearing (1).

D

Install the left side bearing using the bushing, seal
installer 09913–76010 and a hammer.

Important: Coat the inner parts; bearing, washer, shim
etc. with gear fluid.

D103B798

2. Install the speedometer drive gear and differential

right side bearing.

D

Insert the speedometer drive gear(1).

D

Insert the differential right side bearing (2).

D

Install the right side bearing using the bushing,
seal installer 09913–76010 and a hammer.