[ RM-1 ]
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LTD.
FOREWORD
This REPAIR...
[ RM-2 ]
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LTD.
ABBREVIATIONS
ASSY ....
[ RM-3 ]
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LTD.
ABBREVIATIONS
SLT .....
[ RM-4 ]
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LTD.
BLANK
[ RM-5 ]
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LTD.
TABLE OF CONTENTS
FO...
[ RM-6 ]
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LTD.
DESCRIPTION
The new ...
[ RM-7 ]
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LTD.
OPERATION
C 2B3B 2
B...
[ RM-8 ]
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LTD.
OPERATION
S1 S2 ST C...
[ RM-9 ]
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LTD.
REPAIR PROCEDURES
GE...
[ RM-10 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-11 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-12 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-13 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-14 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-15 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-16 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-17 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-18 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-19 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-20 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-21 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-22 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-23 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-24 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-25 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-26 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-27 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-28 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-29 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-30 ] REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO...
[ RM-31 ]REMOVAL OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO....
[ RM-32 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-33 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-34 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-35 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-36 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-37 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-38 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-39 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-40 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-41 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-42 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-43 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-44 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-45 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-46 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-47 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-48 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-49 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-50 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-51 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-52 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-53 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-54 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-55 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-56 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-57 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-58 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-59 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyr...
[ RM-60 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copy...
[ RM-61 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-62 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-63 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-64 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-65 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-66 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-67 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-68 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-69 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-70 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-71 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-72 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-73 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-74 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-75 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-76 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-77 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-78 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-79 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-80 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-81 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-82 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-83 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-84 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-85 ]INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN A...
[ RM-86 ] INSTALLATION OF COMPONENT PARTS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN ...
[ RM-87 ]SERVICE SPECIFICATIONS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LT...
[ RM-88 ] SERVICE SPECIFICATIONS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., L...
[ RM-89 ]SERVICE SPECIFICATIONS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., LT...
[ RM-90 ] SERVICE SPECIFICATIONS
DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002)
© All Rights Copyright AISIN AW CO., L...
Upcoming SlideShare
Loading in …5
×

124361534 daewoo-8140le-repair

1,730 views

Published on

transmision toyota

Published in: Automotive, Business
0 Comments
2 Likes
Statistics
Notes
  • Be the first to comment

No Downloads
Views
Total views
1,730
On SlideShare
0
From Embeds
0
Number of Embeds
6
Actions
Shares
0
Downloads
61
Comments
0
Likes
2
Embeds 0
No embeds

No notes for slide

124361534 daewoo-8140le-repair

  1. 1. [ RM-1 ] DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. FOREWORD This REPAIR MANUAL covers Disassembly, Inspection and Assembly procedures for the following Automatic Transmission: All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without notice. QUALITY ASSURANCE DEPT. All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of AISIN AW CO., LTD. First Printing: Jul, 2003 © 2003 Automotic Transmission Engine Type REF No. 81-40LE DAEWOO: 96 484 421 AW: 30510-81C008 FAN I 1.5L SOHC DW-01M-MRM002
  2. 2. [ RM-2 ] DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. ABBREVIATIONS ASSY ............................................................ Assembly A/T .......................................... Automatic Transmission ATF ................................ Automatic Transmission Fluid B1 ........................................... O/D & 2nd Coast Brake B2 .................................................................2nd Brake B3 ................................................ 1st & Reverse Brake C1 .........................................................Forward Clutch C2 ............................................................ Direct Clutch C3 ........................................................ Reverse Clutch F1.................................................... 1 Way Clutch No.1 F2.................................................... 1 Way Clutch No.2 O/D ............................................................. Over Drive V/B .............................................................. Valve Body FIPG ...................................... Formed In Place Gasket SST...............................................Service Special Tool TT .................................................... Tightening Torque T/M........................................................... Transmission T/C .................................................... Torque Converter FR .........................................................................Front RR......................................................................... Rear MID .................................................................... Middle DIA................................................................. Diameter B/G....................................................................Bearing
  3. 3. [ RM-3 ] DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. ABBREVIATIONS SLT ........................ Throttle Pressure Control Solenoid S1,S2 .....................................Shift Solenoid No.1,No.2 ST ....................................................... Timing Solenoid SL ................................................... Lock-Up Solenoid Th.................................................................. Thickness L......................................................................... Length V........................................................................... Valve Acum......................................................... Accumulator Cont. ................................................................. Control Reg. .............................................................. Regulator Press...............................................................Pressure Mod............................................................... Modulator Pla.................................................................. Planetary STD................................................................ Standard LUB....................................................................... Lube HSG ................................................................. Housing Diff ............................................................... Differential
  4. 4. [ RM-4 ] DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. BLANK
  5. 5. [ RM-5 ] DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. TABLE OF CONTENTS FOREWORD ........................................................................................ RM-1 ABBREVIATIONS ................................................................................ RM-2 DESCRIPTION..................................................................................... RM-6 OPERATION ........................................................................................ RM-7 REPAIR PROCEDURES...................................................................... RM-9 GENERAL REPAIR INSTRUCTIONS................................................. RM-9 REMOVAL OF COMPONENT PARTS............................................... RM-10 ASSEMBLY AND DISASSEMBLY OF CONPONENTS .................... RM-32 1. OIL PUMP .......................................................................................................... RM-32 2. DIRECT CLUTCH (C2) ...................................................................................... RM-36 3. PLANETARY RING GEAR ................................................................................ RM-43 4. 1 WAY CLUTCH................................................................................................. RM-45 5. FORWARD AND REVERSE CLUTCH (C1,C3)................................................. RM-48 6. COUNTER DRIVEN GEAR................................................................................ RM-56 7. VALVE BODY .................................................................................................... RM-59 8. DIFFERENTIAL ................................................................................................. RM-60 INSTALLATION OF COMPONENT PARTS....................................... RM-61 SERVICE SPECIFICATIONS............................................................. RM-87
  6. 6. [ RM-6 ] DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. DESCRIPTION The new automatic transmission AW 81-40LE is an electronically controlled 4-speed automatic transmission with Lock-up mechanism. The transmission is mainly composed of the torque converter with lock up clutch, newly developed 4-speed planetary gear unit, the hydraulic control system and the electric control system. SECTIONAL VIEW AW 81-40LE
  7. 7. [ RM-7 ] DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. OPERATION C 2B3B 2 B1 C 1 C 3 F1 F2 Differential Gear Assy Counter Drive G ear Assy C ounter Driven G ear Assy FROM T /C
  8. 8. [ RM-8 ] DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. OPERATION S1 S2 ST C1 C2 C3 B1 B2 B3 F1 F2 ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF V<9 ON ON OFF OFF OFF ON OFF OFF ON OFF OFF V>=11 ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF 1st ON ON OFF ON OFF OFF OFF OFF OFF OFF ON 2nd ON OFF OFF ON OFF OFF OFF ON OFF ON OFF 3rd OFF OFF OFF ON ON OFF OFF ON OFF OFF OFF 3<=>4 OFF ON ON ON<=>OFF ON OFF OFF<=>ON ON OFF OFF OFF 4th OFF ON OFF OFF ON OFF ON ON OFF OFF OFF 1st ON ON OFF ON OFF OFF OFF OFF OFF OFF ON 2nd ON OFF OFF ON OFF OFF ON ON OFF ON OFF 3rd OFF OFF OFF ON ON OFF OFF ON OFF OFF OFF 1st ON ON OFF ON OFF OFF OFF OFF ON OFF ON 2nd ON OFF OFF ON OFF OFF ON ON OFF ON OFF D 2 L Brake 1 Way Clutch R N POSITION P Solenoid Clutch
  9. 9. [ RM-9 ] DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. REPAIR PROCEDURES GENERAL REPAIR INSTRUCTIONS 1. Most repair operations begin with an overview illustration. 2. It identifies the components and shows how the parts fit together. 3. The procedures are presented in a step-by-step format: (1) The illustration shows what to do and where to do it. (2) The task heading tells what to do. (3) The detailed text tells how to perform the task and gives other information such as specifications and warnings. You never have to leave the procedure to look up your specs. 1. During disassembly, keep parts in order to facilitate reassembly. 2.(1) Always replace gaskets, O-rings and oil seals etc. with new ones. (2) Parts which cannot be reused are indicated by the symbol “ ”. 3. When necessary, use a sealer on gaskets to prevent leaks. 4. Carefully observe all specification for bolt tightening torque. Always use a torque wrench. 5. Use of SST may be required, depending on the nature of the repair. Be sure to use SST where specified and follow the proper work procedure.
  10. 10. [ RM-10 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. REMOVAL OF COMPONENT PARTS SS-01-81A Breather Hose Clip No.1 Breather Plug Bracket Union Transaxle Revolution Sensor "O" Ring "O" Ring "O" Ring Non Reusable Part "O" Ring Gasket Speed Sensor Union Screw Plug
  11. 11. [ RM-11 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. Gasket Valve Body Assembly Gasket Oil Seal Torque Converter Oil Seal Newtral Start Switch Spacer "O" ring "O" ring "O" ring "O" ring Brake Drum Gasket Apply Gasket "O" ring SS-01-01A Non Reusable Part
  12. 12. [ RM-12 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-02A "O" Ring "O" Ring O/D Brake Piston 2nd Brake Piston 1st & Reverse Brake Piston Forward Clutch Hub Apply Gasket Transaxle Rear Cover Forward Clutch & Reverse Clutch Assembly One-Way Clutch Assembly Rear Planetary Sun Gear Front Planetary Sun Gear Planetary Gear Planetary Ring Gear "O" Ring "O" Ring Non Reusable Part
  13. 13. [ RM-13 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-03A Oil SealDifferential Gear Oil Pump Counter Driven Gear Counter Drive Gear Nut Apply Gasket Non Reusable Part Direct Clutch Assembly Direct Clutch Hub
  14. 14. [ RM-14 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 3. REMOVE UNION (1) Remove the 2 unions. (2) Remove the 2 “O” rings from the unions. 4. REMOVE SCREW PLUG (1) Remove the screw plug from the transaxle case. (2) Remove the “O” ring from the screw plug. 6. REMOVE INPUT SPEED SENSOR AND NO.1 BREATHER PLUG (1) Remove the 1 bolt and input speed sensor. (2) Remove the clip and breather hose. (3) Remove the No.1 breather plug. (4) Remove the “O” ring from the No.1 breather plug. 5. REMOVE BRACKET (1) Remove the 1 bolt and bracket. SEPARATE EXTERNAL PARTS 1. REMOVE TORQUE CONVERTER 2. REMOVE NEUTRAL START SWITCH (1) Remove the nut, washer and control lever. (2) Using a screwdriver, unstake the lock washer. (3) Remove the 2 bolts and nut, and pull out the neutral start switch. SS-01-04A SS-01-05A SS-01-06A SS-01-80A SS-01-07A
  15. 15. [ RM-15 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 8. REMOVE OIL PAN AND GASKET (1) Remove the 18 bolts. (2) Remove the oil pan and gasket. (3) Remove the gasket and drain plug from the oil pan. 9. EXAMINE PARTICLES IN PAN (1) Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle: Steel (magnetic)..... bearing, gear and plate ware Brass (non-magnetic)..... bushing wear 10. REMOVE OIL STRAINER (1) Remove the 3 bolts and oil strainer. (2) Remove the gasket from the oil strainer. 7. PLACE TRANSAXLE ON WOODEN BLOCKS SS-01-08A SS-01-09A SS-01-10A SS-01-11A SS-01-12A
  16. 16. [ RM-16 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. (3) Support the valve body assembly and remove the 14 bolts. (4) Disconnect the manual valve control rod from the manual valve lever, then remove the valve body assembly. 12. REMOVE CHECK VALVE (1) Remove the check valve and spring. 13. REMOVE BRAKE DRUM GASKET (1) Remove the brake drum gasket. 14. REMOVE APPLY GASKET 11. REMOVE VALVE BODY ASSEMBLY (1) Remove the bolt and ATF temperature sensor with clamp. (2) Disconnect the 5 connectors. SS-01-13A SS-01-14A SS-01-15A SS-01-16A SS-01-17A
  17. 17. [ RM-17 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. (3) Remove the 2 “O” rings from the C2 accumulator piston. (6) Remove the 2 “O” rings from the C1 accumulator piston. (4) Apply compressed air (4.0 kgf/cm2 ) to the oil hole and remove the C1 accumulator piston and spring. (5) Remove the spring. CAUTION: Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing. 15. REMOVE ACCUMULATOR SPRING AND PISTON (1) Apply compressed air (4.0 kgf/cm2) to the oil hole and remove the C2 accumulator piston and spring. (2) Remove the spring. CAUTION: Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing. SS-01-18A SS-01-19A SS-01-20A SS-01-21A
  18. 18. [ RM-18 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 16. REMOVE TRANSAXLE WIRE (1) Remove the 1 bolt. (2) Remove the transaxle wire from the transaxle case. (3) Remove the “O” ring from the transaxle wire. (7) Apply compressed air (4.0 kgf/cm2 ) to the oil hole and remove the B1 accumulator piston and spring. CAUTION: Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing. (8) Remove the 2 “O” rings from the B1 accumulator piston. SS-01-22A SS-01-23A SS-01-24A SS-01-25A
  19. 19. [ RM-19 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 21. REMOVE DIFFERENTIAL GEAR ASSEMBLY 18. REMOVE TRANSAXLE HOUSING (1) Remove the 16 bolts. (2) Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case. CAUTION: Differential gear assembly may be accidentally removed when the transaxle housing is removed. 19. INSPECT INPUT SHAFT END PLAY (1) Using a dial indicator, measure the input shaft end play. 20. REMOVE OIL PUMP (1) Remove the 6 bolts and oil pump. 17. REMOVE VEHICLE SPEED SENSOR (1) Remove the 1 bolt and the vehicle speed sensor. SS-01-26A SS-01-27A SS-01-28A SS-01-29A SS-01-82A
  20. 20. [ RM-20 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 25. REMOVE COUNTER DRIVEN GEAR ASSEMBLY 23. REMOVE DIRECT CLUTCH ASSEMBLY (1) Remove the direct clutch assembly from the transaxle case. (2) Remove the thrust needle roller bearing from the direct clutch assembly. 24. REMOVE DIRECT CLUTCH HUB (1) Remove the direct clutch hub, thrust needle roller bearing and thrust bearing race from the transaxle case. 22. REMOVE APPLY GASKET SS-01-30A SS-01-31A SS-01-32A SS-01-33A SS-01-34A
  21. 21. [ RM-21 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. (2) Remove the thrust needle roller bearing and thrust bearing race from the forward & reverse clutch assembly. 26. REMOVE TRANSAXLE REAR COVER (1) Remove the 9 bolts. (2) Tap on the circumference of the transaxle rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case. 27. REMOVE 4 APPLY GASKETS 28. REMOVE 2ND COAST & O/D BRAKE FLANGE, DISC AND PLATE (1) Remove the flange, 2 discs and 2 plates from the transaxle case. 29. REMOVE FORWARD & REVERSE CLUTCH ASSEMBLY (1) Remove the thrust needle roller bearing and forward & reverse clutch assembly. SS-01-35A SS-01-36A SS-01-37A SS-01-38A SS-01-39A
  22. 22. [ RM-22 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. (3) Remove the thrust needle roller bearing and planetary carrier thrust washer from the rear planetary sun gear and 1 way clutch assembly. (2) Remove the thrust bearing race and thrust needle roller bearing from the forward clutch hub. 31. REMOVE REAR PLANETARY SUN GEAR AND 1 WAY CLUTCH ASSEMBLY (1) Remove the rear planetary sun gear and 1 way clutch assembly. 30. REMOVE FORWARD CLUTCH HUB (1) Remove the forward clutch hub from the transaxle case. SS-01-40A SS-01-41A SS-01-42A SS-01-43A SS-01-44A (2) Remove the thrust bearing race from the rear planetary sun gear and 1 way clutch assembly.
  23. 23. [ RM-23 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. (3) Remove the 2 “O” rings from the 2nd brake piston. 32. REMOVE FRONT PLANETARY SUN GEAR (1) Remove the front planetary sun gear from the transaxle case. (2) Remove the thrust bearing race from the front planetary sun gear. 33. REMOVE 2ND BRAKE (1) Using SST and a press, remove the 2 snap rings, 2ND brake and 2ND brake piston return spring. CAUTION: Stop the press when the 2nd brake is lowered 1 - 2 mm from the snap ring groove, preventing the 2nd brake from being deformed. (2) Apply compressed air (4.0 kgf/cm2 ) to the 2nd brake to remove the 2nd brake piston from the 2nd brake clutch cylinder. CAUTION: Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing. (4) Remove the 1 way clutch assembly and thrust washer from the rear planetary sun gear. SS-01-45A SS-01-46A SS-01-47A SS-01-48A SS-01-83A SST
  24. 24. [ RM-24 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. (2) Remove the No.2 one-way clutch from the planetary gear. (3) Remove the anti-rattle clip. 35. REMOVE COUNTER DRIVE GEAR AND PLANETARY RING GEAR (1) Fix the counter drive gear with the parking lock pawl. 34. REMOVE NO.2 1 WAY CLUTCH AND PLANETARY GEAR (1) Remove the No.2 1 way clutch and planetary gear from the transaxle case. (4) Remove the 2 plates, 2 discs and flange. SS-01-49A SS-01-50A SS-01-51A SS-01-52A
  25. 25. [ RM-25 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. (4) Remove the nut. CAUTION: Remove the nut without unstaking the planetary ring gear. If chisel or other tool is used to unstake the planetary ring gear, such impact may damage the bearing. (3) Using SST and a hammer, unstake the counter drive gear nut. SS-01-53A SS-01-84A SST SST SS-01-86C (2) Using SST, lift the transaxle case.
  26. 26. [ RM-26 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-54A SS-01-55A (5) Install the 3 bolts to the counter drove gear. Bolt (M6): L = 40 - 80 mm Pitch = 1.0 mm (6) Rotate 3 bolts in order and remove the counter drive gear and planetary ring gear. 36. REMOVE PARKING LOCK PAWL (1) Remove the 2 bolts and parking lock pawl bracket. (2) Remove the parking lock pawl shaft, torsion spring and parking lock pawl. SS-01-62A SS-01-63C SST
  27. 27. [ RM-27 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. (5) Remove the parking lock rod from the manual valve lever. (3) Using a pin punch and hammer, drive out the pin. (4) Remove the manual valve lever shaft and manual valve lever. (2) Using a chisel and hammer, unstake and remove the spacer. 37. REMOVE MANUAL VALVE LEVER SHAFT (1) Remove the 1 bolt and manual detent spring. SS-01-56A SS-01-57A SS-01-58A SS-01-59A SS-01-60A
  28. 28. [ RM-28 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. (4) Remove the 2 “O” rings from the 1st & reverse brake piston. 38. REMOVE 1ST & REVERSE BRAKE (1) Using SST and a press, remove the snap ring. (2) Remove the flange, 4 plates, 4 discs and return spring. (3) Apply compressed air (4.0 kgf/cm2 ) to the transaxle case to remove the 1st & reverse brake piston. CAUTION: Blowing off the air may cause the piston's jump-out. When removing thee piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing. (6) Using a screwdriver, remove the oil seal. SS-01-61A SS-01-65A SS-01-66A SS-01-83A SST SS-01-64A
  29. 29. [ RM-29 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 41. REMOVE OIL RESERVOIR LOCK PLATE (1) Remove the 3 bolts and oil reservoir lock plate from the transxle housing. 42. REMOVE APPLY PIPE (1) Remove the 1 bolt and No.1 transaxle apply pipe clamp from the transaxle housing. (2) Remove the transaxle lube apply pipe and differential gear lube apply pipe from the transaxle housing. 43. REMOVE OIL SEAL (1) Using SST and a hammer, remove the oil seal from the transaxle housing. 40. REMOVE OUTER TAPERED ROLLER BEARING RACE AND SHIM FROM TRANSAXLE CASE (1) Using SST, remove the outer tapered roller bearing race and shim. 39. REMOVE NO.1 TRANSAXLE CASE PLATE (1) Remove the 1 bolt and No.1 transaxle case plate from the transaxle case. SS-01-67A SS-01-70A SS-01-71A SST SS-01-72A SST SS-01-68A
  30. 30. [ RM-30 ] REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 44. REMOVE OIL SEAL OF TRANSAXLE HOUSING (1) Using SST and a hammer, remove the oil seal. SS-01-73A SST SS-01-75A SS-01-85A SST (2) Remove the O/D brake return spring. 45. REMOVE O/D BRAKE PISTON (1) Using SST and a press, remove the snap ring. CAUTION: Stop the press when the O/D brake piston is lowered 1 - 2 mm from the snap ring grove, preventing the O/D brake piston from being deformed. SS-01-76A SS-01-77A (3) Apply compressed air (4.0 kgf/cm2 ) to the transaxle rear cover to remove the O/D brake piston. CAUTION: Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing. (4) Remove the 2 “O” rings from the O/D brake piston.
  31. 31. [ RM-31 ]REMOVAL OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 46. DISASSEMBLE TRANSAXLE REAR COVER (1) Remove the 2 seal rings from the transaxle rear cover. CAUTION: Do not expand the seal ring excessively. (2) Remove the 4 screw plugs and 4 “O” rings from the transaxle rear cover. SS-01-78A SS-01-79A
  32. 32. [ RM-32 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 1. OIL PUMP SS-02-01A Oil Pump Body Oil Pump Drive Gear Oil Pump Drive Gear Stator Shaft
  33. 33. [ RM-33 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. DISASSEMBLY OF OIL PUMP 1. CHECK OIL PUMP DRIVE GEAR ROTATION (1) Turn the drive gear with the 2 screwdrivers and make sure it rotates smoothly. CAUTION: Be careful not to damage the oil lip. 2. REMOVE STATOR SHAFT (1) Remove the 8 bolts and stator shaft. CAUTION: Be careful not to let the drive gear drop as it might come off attached to the stator shaft. 3. REMOVE OIL PUMP DRiVE GEAR AND DRIVEN GEAR 2. CHECK TIP CLEARANCE OF DRIVEN GEAR (1) Measure the tip clearance between the driven gear teeth and drive gear teeth. INSPECTION OF OIL PUMP 1. CHECK BODY CLEARANCE OF DRIVEN GEAR (1) Push the driven gear to one side of the body. Using a feeler gauge, measure the clearance. SS-02-02A SS-02-03A SS-02-04A SS-02-05A SS-02-06A Body Clearance STD. 0.10-0.17 mm MAX 0.22 mm Tip Clearance Driven STD. 0.07-0.15 mm MAX 0.20 mm
  34. 34. [ RM-34 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 3. CHECK SIDE CLEARANCE OF BOTH GEAR (1) Using a steel straight edge and feeler gauge, measure the side clearance of both gears. If the side clearance is greater the the maximum, select the drive and driven gear. 4. CHECK OIL PUMP BODY BUSHING (1) Using a dial indicator, measure the inside diameter of the oil pump body bushing. 5. CHECK STATOR SHAFT BUSHING (1) Using a dial indicator, measure the inside diameter of the stator shaft bushings. SS-02-07A SS-02-08A SS-02-09A Side Clearance of STD. 0.02-0.05 mm Drive and Driven Gear MAX 0.10 mm Gear Thickness Mark Drive Gear Type 1 Th= 8.440-8.449 mm 2 Th= 8.450-8.459 mm 3 Th= 8.460-8.470 mm 4 Th= 8.471-8.480 mm 5 Th= 8.481-8.490 mm Mark Driven Gear 1 Th= 8.440-8.449 mm 2 Th= 8.450-8.459 mm 3 Th= 8.460-8.470 mm 4 Th= 8.471-8.480 mm 5 Th= 8.481-8.490 mm Body Bush STD. 38.113-38.138 mm MAX 38.188 mm Stator Shaft Bush STD. 18.424-18.450 mm MAX 18.50 mm
  35. 35. [ RM-35 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 3. CHECK PUMP DRIVE GEAR ROTATION (1) Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly. CAUTION: Be careful not to damage the oil lip. 2. INSTALL STATOR SHAFT (1) Align the stator shaft with each bolt hole. (2) Install the 8 bolts. TT = 7.8-11.8 N.m (80-120 kgf.cm) ASSEMBLY OF OIL PUMP 1. INSTALL OIL PUMP DRIVE GEAR AND DRIVEN GEAR SS-02-04A SS-02-03A SS-02-02A
  36. 36. [ RM-36 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 2. DIRECT CLUTCH SS-03-01A Seal Ring Input Shaft Sub-assembly Return Spring Snap Ring "O" Ring Non Reusable Part "O" Ring Piston Snap Ring Flange Plate Disc
  37. 37. [ RM-37 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 2. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring. 3. REMOVE FLANGE, DISC AND PLATE (1) Remove the flange, 2 discs and 2 plates. DISASSEMBLY OF DIRECT CLUTCH 1. CHECK PISTON STROKE OF DIRECT CLUTCH (1) Install the direct clutch and thrust needle roller bearing on the oil pump. (2) Using a dial indicator, measure the direct clutch piston stroke while applying and releasing compressed air (4.0 kgf/cm2 ).SS-03-02A SS-03-03A SS-03-04A Piston Stroke 0.40-0.70 mm
  38. 38. [ RM-38 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 4. REMOVE DIRECT CLUTCH RETURN SPRING (1) Place SST on the return spring and compress. (2) Using a snap ring expander, remove the snap ring. CAUTION: Stop the press when the piston return spring is lowered to the place 1-2 mm from the snap ring groove, preventing the piston return spring from being deformed. Do not expand the snap ring excessively. (3) Remove the direct clutch return spring. 5. REMOVE DIRECT CLUTCH PISTON (1) Install the direct clutch on the oil pump. (2) Apply compressed air (4.0 kgf/cm2 ) to the oil pump to remove the direct clutch piston. CAUTION: Blowing off the air may cause the piston' jump-put. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing. HINT: When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using needle nose pliers with vinyl tape on the tip. SS-03-05A SST SS-03-06A SS-03-07A
  39. 39. [ RM-39 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 6. REMOVE “O” RING (1) Using a small screwdriver, remove the “O” ring from the direct clutch piston. (2) Remove the “O” ring from the input shaft. 7. REMOVE SEAL RING (1) Remove the 2 seal rings from the input shaft. CAUTION: Do not expand the ring ends excessively. 2. CHECK DIRECT CLUTCH RETURN SPRING (1) Using vernier calipers, measure the free length of the spring together with the spring sheet. SS-03-09A SS-03-10A INSPECTION OF DIRECT CLUTCH 1. INSPECT DISC AND FLANGE (1) Check to see if the sliding surface of the disc, plate and flange are worm or burnt. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed number is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. SS-03-11A SS-03-12A SS-03-08A STD 36.04 mm Piston Return Spring Free Length
  40. 40. [ RM-40 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 3. CHECK DIRECT CLUTCH PISTON (1) Check that the check ball is free by shaking the piston. (2) Check that the valve does not leak by applying low-pressure compressed air. 2. INSTALL O-RING (1) Coat a new “O” ring with ATF, and install the “O” ring to the input shaft. (2) Coat a new “O” ring with ATF, and install the “O” ring to the direct clutch piston. 3. INSTALL DIRECT CLUTCH PISTON (1) Coat the direct clutch piston with ATF, install it to the direct clutch drum. CAUTION: Be careful no to damage the lip seal of direct clutch piston. SS-03-13A ASSEMBLY OF DIRECT CLUTCH 1. INSTALL SEAL RING (1) Install the 2 seal rings to the input shaft. CAUTION: Do not expand the ring ends excessively. SS-03-10A SS-03-09A SS-03-14A SS-03-08A
  41. 41. [ RM-41 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 4. INSTALL DIRECT CLUTCH RETURN SPRING. (1) Install the direct clutch return spring. (2) Place SST on the return spring and compress. (3) Using a snap ring expander, install the snap ring. CAUTION: Stop the press when the piston return spring is lowered to the place 1 - 2 mm from the snap ring groove, preventing the piston return spring from being deformed. Do not expand the snap ring excessively. (2) Using a screwdriver, remove the snap ring. (3) Check that the end gap of the snap ring is not aligned with one of the cutouts. SS-03-06A SS-03-05A SST SS-03-03A SS-03-15A F P D 5. INSTALL PLATE, DISC AND FLANGE (1) Install the 2 plates, 2 discs and flange. HINT: Before installing the discs, coat them with ATF.
  42. 42. [ RM-42 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 6. CHECK PISTON STROKE OF DIRECT CLUTCH (1) Install the direct clutch on the oil pump. (2) Using a dial indicator, measure the direct clutch piston stroke while applying and releasing compressed air (4.0kgf/cm2 ). SS-03-02A HINT: If the piston stroke is out of standards, select another flange. Piston Stroke 0.40-0.70 mm Flange Thickness Th= 3.0 mm Type Th= 3.2 mm Th= 3.4 mm
  43. 43. [ RM-43 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 3. PLANETARY RING GEAR DISASSEMBLY OF PLANETARY RING GEAR 2. REMOVE PLANETARY RING GEAR FLANGE (1) Remove the planetary ring gear flange from the planetary ring gear. DISASSEMBLY OF PLANETARY RING GEAR 1. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring. SS-04-01A Planetary Ring Gear Flange Non Reusable Part Snap Ring Planetary Ring Gear SS-04-02A SS-04-03A
  44. 44. [ RM-44 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 2. INSTALL SNAP RING (2) Using a screwdriver, install the snap ring. SS-04-03A ASSEMBLY OF PLANETARY RING GEAR 1. INSTALL PLANETARY RING GEAR FLANGE (1) Install a new planetary ring gear flange to the planetary ring gear. SS-04-02A
  45. 45. [ RM-45 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 4. 1 WAY CLUTCH 1. CHECK OPERATION OF 1 WAY CLUTCH (1) Install the 1 way clutch and thrust washer to the rear planetary sun gear. (2) Hold the rear planetary sun gear and turn the 1 way clutch. The 1 way clutch should turn freely clockwise and should lock counterclockwise. 2. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring. DISASSEMBLY OF 1 WAY CLUTCH Freely Lock SS-05-02A SS-05-03A SS-05-01A Snap Ring Retainer 2nd Brake Hub 1 Way Clutch
  46. 46. [ RM-46 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 3. REMOVE 1 WAY CLUTCH 4. REMOVE RETAINER (1) Using a small screwdriver, remove the retainer. 2. INSTALL 1 WAY CLUTCH 3. INSTALL SNAP RING (1) Using a screwdriver, install the snap ring. ASSEMBLY OF 1 WAY CLUTCH 1. INSTALL RETAINER (1) Install the retainer to the 2nd brake hub. HINT: Install the retainer closely. SS-05-04A SS-05-05A SS-05-04A SS-05-03A
  47. 47. [ RM-47 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 4. CHECK OPERATION OF 1 WAY CLUTCH (1) Install the 1 way clutch and thrust washer to the rear planetary sun gear. (2) Hold the rear planetary sun gear and turn the 1 way clutch. The 1 way clutch should turn freely clockwise and should lock counterclockwise. Freely Lock SS-05-02A
  48. 48. [ RM-48 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 5. FORWARD AND REVERSE CLUTCH SS-06-01C "O" Ring Forward Clutch Drum"O" Ring Non Reusable Part Intermediate Shaft Sub-assembly Forward Clutch Piston Forward Clutch Return Spring Clutch Balancer Snap Ring Snap Ring Snap Ring Flange Flange Disc Disc Plate Plate Flange Seal Ring
  49. 49. [ RM-49 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 2. CHECK PISTON STROKE OF FORWARD CLUTCH (1) Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover. (2) Using a dial indicator and measuring terminal (SST), measure the forward clutch piston stroke while applying and releasing compressed air (4.0 kgf/cm2 ). HINT: The forward and reverse clutch will come out as you apply the compressed air. Therefore, while the checking is being done, press on the input shaft of the forward and reverse clutch using stamping machine or alike so that the pressure is not applied on the forward and reverse clutch. 3. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring. SS-06-02A SS-06-03A SST SST SS-06-04A DISASSEMBLY OF FORWARD AND REVERSE CLUTCH 1. CHECK PISTON STROKE OF REVERSE CLUTCH (1) Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover. (2) Using a dial indicator, measure the reverse clutch piston stroke while applying and releasing compressed air (4.0 kgf/cm2 ). Piston Stroke 0.86-1.26 mm Piston Stroke 1.30-1.50 mm
  50. 50. [ RM-50 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 4. REMOVE FLANGE, DISC AND PLATE (1) Remove the 2 flanges, 2 discs and plate from the reverse clutch drum. 5. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring. 6. REMOVE FLANGE, DISC AND PLATE (1) Remove the flange, 4 discs and 4 plates from the forward clutch drum. 7. REMOVE FORWARD CLUTCH RETURN SPRING (1) Place SST on the clutch balancer and compress the springs with a press. (2) Using a snap ring expander, remove the snap ring. CAUTION: Stop the press when the clutch balancer is lowered to the place 1 - 2 mm from the snap ring groove, preventing the clutch balancer from being deformed. Do not expand the snap ring excessively. (3) Remove the clutch balancer and forward clutch return spring. SS-06-05A SS-06-06A SS-06-07A SS-06-08A SST SS-06-19A
  51. 51. [ RM-51 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 8. REMOVE FORWARD CLUTCH PISTON (1) Install the forward and reverse multiple disc clutch on the transaxle rear cover. (2) Apply compressed air (4.0 kgf/cm2 ) to the transaxle rear cover to remove the forward clutch piston. CAUTION: Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing. HINT: When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed or remove the piston using a needle nose pliers with vinyl tape on the tip. 9. REMOVE FORWARD CLUTCH DRUM (1) Apply compressed air (4.0 kgf/cm2 ) to the transaxle rear cover to remove the forward clutch drum. CAUTION: Blowing off the air may cause the drum's jump-out. When removing the drum, hold it with your hand using a waster cloth. Take care not to splash ATF when air-blowing. HINT: When the drum cannot be removed as it is slanted, either blow the air again with the protruding side pushed or remove the drum using a needle nose pliers with vinyl tape on the tip. 10. REMOVE “O” RING (1) Using a small screwdriver, remove the “O” ring from the forward clutch drum. SS-06-09A SS-06-10A SS-06-11A
  52. 52. [ RM-52 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. (2) Using a small screwdriver, remove the “O” ring from the intermediate shaft sub- assembly. (2) Coat a new “O” ring with ATF, and install it to the forward clutch drum. ASSEMBLY OF FORWARD AND REVERSE CLUTCH 1. INSTALL “O” RING (1) Coat a new “O” ring with ATF, and install it to the intermediate shaft sub-assembly. SS-06-12A SS-06-13A SS-06-14A SS-06-12A SS-06-11A INSPECTION OF FORWARD AND REVERSE CLUTCH 1. INSPECT DISC AND FLANGE (1) Check to see if the sliding surface of the disc, plate and flange are worn or burnt. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed number is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. 2. CHECK FORWARD CLUTCH RETURN SPRING (1) Using vernier calipers, measure the free length of the spring together with the spring seat. STD 24.04 mm Piston Return Spring Free Length
  53. 53. [ RM-53 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 2. INSTALL FORWARD CLUTCH DRUM (1) Coat the forward clutch drum with ATF, install the forward clutch drum. CAUTION: Be careful not to damage the “O” ring and lip seal of forward clutch drum. 3. INSTALL FORWARD CLUTCH PISTON (1) Coat the forward clutch piston with ATF, install the forward clutch piston. CAUTION: Be careful not to damage the lip seal of forward clutch piston. 4. INSTALL FORWARD CLUTCH RETURN SPRING (1) Install thee forward clutch return spring and clutch balancer. CAUTION: Be careful not to damage the lip seal of forward clutch return spring. (2) Place SST, on the clutch balancer and compress the piston return spring with a press. (3) Using a snap ring expander, install the snap ring. CAUTION: Stop the press when the clutch balancer is lowered to the place 1 - 2 mm from the snap ring groove, preventing the clutch balancer form being deformed. Do not expand the snap ring excessively. SS-06-15A SS-06-16A SS-06-08A SST SS-06-19A
  54. 54. [ RM-54 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 5. INSTALL PLATE, DISC AND FLANGE (1) Install the 4 plates, 4 discs and flange. 6. INSTALL SNAP RING (1) Using a screwdriver, install the snap ring. (2) Check that the end gap of the snap ring is not aligned with one of the cutouts. 7. INSTALL PLATE, DISC AND FLANGE (1) Install the plate, 2 discs and 2 flanges. 8. INSTALL SNAP RING (1) Using a screwdriver, install the snap ring. (2) Check that the end gap of the snap ring is not aligned with one of the cutouts. SS-06-06A SS-06-04A SS-06-17A F P D F D SS-06-18A FP D
  55. 55. [ RM-55 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 9. CHECK PISTON STROKE OF REVERSE CLUTCH (1) Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover. (2) Using a dial indicator, measure the reverse clutch piston stroke while applying and releasing compressed air (4.0 kgf/cm2 ). 10. CHECK PISTON STROKE OF FORWARD CLUTCH (1) Install the forward and reverse clutch and thrust needle roller bearing on the transaxle rear cover. (2) Using a dial indicator and measuring terminal (SST), measure the forward clutch piston stroke while applying and releasing compressed air (4.0 kgf/cm2 ). SS-06-03A SST SST SS-06-02A HINT: If the piston stroke is out of standards, select another flange. HINT: The forward and reverse clutch will come out as you apply the compressed air. Therefore, while the checking is being done, press on the input shaft of the forward and reverse clutch using stamping machine or alike so that the pressure is not applied on the forward and reverse clutch. HINT: If the piston stroke is out of standards, select another flange. Piston Stroke 0.86-1.26 mm Flange Thickness Th= 3.0 mm Type Th= 3.2 mm Th= 3.4 mm Th= 3.6 mm Piston Stroke 1.30-1.50 mm Flange Thickness Th= 3.0 mm Type Th= 3.1 mm Th= 3.2 mm Th= 3.3 mm Th= 3.4 mm Th= 3.5 mm Th= 3.6 mm
  56. 56. [ RM-56 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 6. COUNTER DRIVEN GEAR SS-07-01A Outer Tapered Roller Bearing Race Counter Driven Gear Outer Tapered Roller Bearing Race SS-07-02C SST DISASSEMBLY OF COUNTER DRIVEN GEAR 1. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (1) Using SST and a press, remove the front drive pinion tapered roller bearing rear inner race counter driven gear from the differential drive pinion. (2) Using SST, remove the front drive pinion tapered roller bearing rear outer race and drive pinion washer from the transaxle case. SS-07-03C
  57. 57. [ RM-57 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-07-04C SST SS-07-06C SS-07-07C SS-07-08C SST 3. REMOVE SIFFERENTIAL DRIVEN PINION PLUG (1) Using extension bar and hammer, remove the differential drive pinion plug. 2. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (1) Using SST and a press, remove the front drive pinion tapered roller bearing front inner race from the differential drive pinion. (2) Using SST, remove the front drive pinion tapered roller bearing front outer race from the transaxle housing. SS-07-05C ASSEMBLY OF COUNTER DRIVEN GEAR 1. INSTALL FRONT DRIVE PINION PLUG (1) Using a socket wrench (10 mm) and hammer, install a new differential drive pinion plug to the differential drive pinion. 2.3-2.8 mmPinion plug 2. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (1) Using SST and a press, install the front drive pinion tapered roller bearing front inner race to the differential drive pinion.
  58. 58. [ RM-58 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-07-10C SST SS-07-11C SST SS-07-09C SST SS-07-12C SST (2) Using SST and a hammer, install the front drive pinion tapered roller bearing front outer race to the transaxle housing. (2) Using SST and a hammer, install the pinion washer and front drive pinion tapered roller bearing rear outer race to the transaxle case. 3. INSTALL COUNTER DRIVE GEAR (1) Using SST and a press, install the counter drive gear to the differential drive pinion. 4. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (1) Using SST and a press, install the front drive pinion tapered roller bearing rear inner race to the differential drive pinion.
  59. 59. [ RM-59 ]ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-08-17A 7. VALVE BODY DISASSEMBLY OF VALVE BODY 1. REMOVE SHIFT SOLENOID (NO.1, NO.2, ST, SL) (1) Remove the each bolt and the solenoids. SS-11-01AM No.1 Solenoid ST Solenoid SL Solenoid No.2 Solenoid ASSEMBLY OF VALVE BODY 1. INSTALL SHIFT SOLENOID (NO.1, NO.2, ST, SL) (1) Replace the “O” ring of each solenoid and install the solenoid. CAUTION: Make sure to use new “O” ring and not to damage the “O” ring. (2) Tighten the 7 bolts. TT = 10.0-12.0 N.m (100-200 kgf.cm)SS-11-04AM No.1 Solenoid (20 mm, 49 mm) ST Solenoid (20 mm) SL Solenoid (28 mm, 49mm) No.2 Solenoid (20 mm, 49 mm)
  60. 60. [ RM-60 ] ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 8. DIFFERENTIAL SS-10-01A Differential Assembly Side Bearing Outer Race Side Bearing Outer Race
  61. 61. [ RM-61 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. INSTALLATION OF COMPONENT PARTS RACE AND BEARING SPECIFICATIONS SS-09-01A A BC D E F G (mm) A B C D E F G RASE Outer Dia. --- 30.60 45.50 --- 29.00 --- --- (Front) Inner Dia. --- 19.30 34.95 --- 19.30 --- --- BEARING Outer Dia. 62.00 29.60 46.50 57.50 --- 48.50 30.20 Inner Dia. 43.20 18.10 33.30 42.50 --- 32.50 or 32.90 17.80 RACE Outer Dia. --- 28.20 --- --- --- --- 32.60 (REAR) Inner Dia. --- 18.10 --- --- --- --- 20.50
  62. 62. [ RM-62 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 1. ASSEMBLY TRANSAXLE TEAR COVER (1) Install 4 new “O” rings to the 4 screw plugs. (2) Install the 4 screw plugs with the “O” rings to the transaxle rear cover. TT = 5.9-8.8 N.m (60-90 kgf.cm) (3) Install the 2 seal rings to the transaxle rear cover. 2. CHECK O/D & 2ND COAST BRAKE PISTON RETURN SPRING (1) Using vernier calipers, measure the free length of the spring together with the spring seat. 3. INSTALL O/D & 2ND COAST BRAKE PISTON (1) Coat 2 new “O” rings with ATF, install them to the O/D & 2nd coast brake piston. (2) Coat the O/D & 2nd coast brake piston with ATF, install it to the transaxle rear cover. CAUTION: Be careful not to damage the “O” rings of the O/D & 2nd coast brake piston. SS-01-79A SS-01-78A SS-09-02A SS-01-77A SS-09-03A STD 18.99 mm Piston Return Spring Free Length
  63. 63. [ RM-63 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 6. INSTALL APPLY PIPE (1) Install the transaxle lube apply pipe and differential gear lube apply pipe to the transaxle housing. (2) Install the No.1 transaxle apply pipe clamp to the transaxle housing with 1 bolt. TT = 3.9-6.9 N.m (40-70 kgf.cm) 7. INSTALL OIL RESERVOIR LOCK PLATE (1) Install the oil reservoir lock plate to the transaxle housing with the 3 bolts. TT = 3.9-6.9 N.m (40-70 kgf.cm) SS-01-71A SS-01-70A (3) Using SST and a press, install the O/D & 2nd coast brake return spring and snap ring to transaxle rear cover. CAUTION: Stop the press when the O/D & 2nd coast brake piston is lowered 1 - 2 mm from the snap ring groove, preventing the O/D & 2nd coast brake piston from being deformed. 4. INSTALL TRANSAXLE HOUSING OIL SEAL (1) Using SST and a hammer, drive in a new oil seal. 5. INSTALL OIL SEAL (1) Using SST and a hammer, drive in a new oil seal. A = 0 mm (2) Coat the lip of oil seal with MP grease. SS-01-85A SST SS-09-05A SST SST Oil seal in depth 2.6-3.6 mm SS-09-07A A SST
  64. 64. [ RM-64 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. 8. INSTALL TRANSAXLE CASE OIL SEAL (1) Using SST and a hammer, drive in a new oil seal. SS-09-09A SST SST Oil seal in depth 3.8-4.8 mm 9. INSTALL NO.1 TRANSAXLE CASE PLATE (1) Install the No.1 transaxle case plate to the transaxle case with the bolt. TT = 7.8-11.8 N.m (80-120 kgf.cm) 10. ADJUST COUNTER DRIVEN GEAR PRELOAD (1) Install the differential gear to the transaxle case. (2) Install the transaxle housing and tighten the 16 bolts of the transaxle housing temporarily. (3) Tighten 8 or 9 bolts out of 16 bolts of the transaxle housing completely. TT = 23.5-35.5 N.m (240-360 kgf.cm) (4) Using a SST, turn the differential gear assembly right and left 2 or 3 times to allow the bearing settle. SS-01-67A SS-09-11A SS-09-12A SS-01-26A
  65. 65. [ RM-65 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-09-14A SS-01-26A SS-09-13A SS-09-12A (6) Remove the transaxle housing and install the counter driven gear. (7) Install the transaxle housing and tighten the 16 bolts of the transaxle housing temporarily. (8) Tighten the bolts of the transaxle housing in the same manner as in step (3). TT = 23.5-35.5 N.m (240-360 kgf.cm) 9) Using a SST, turn the differential gear assembly right and left 2 or 3 times to allow the bearing settle. (10) Using SST and a small torque wrench, measure the preload of the differential gear. From this valve deduct the value measured in step (4). This is the preload of the counter driven gear. New Bearing 0.78-13.7 N.m (8.0-14.0 kgf.cm) Reused Bearing 0.39-0.69 N.m (4.0-7.0 kgf.cm) (5) Using SST and small torque wrench, measure the preload of the differential gear. HINT: Note down the measured valve. SS-09-13A
  66. 66. [ RM-66 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. HINT: When the preload is larger than the specification, select a thinner adjuster shim. When the preload is smaller than the specification, select a thicker adjuster shim. 11. CHECK 1ST & REVERSE BRAKE PISTON RETURN SPRING (1) Using vernier calipers, measure the free length of the spring together with spring seat. 12. INSPECT DISC, PLATE AND FLANGE OF 1ST & REVERSE BRAKE (1) Check to see if the sliding surface of the disc, plate and flange are worn or burnt. CAUTION: If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. SS-09-16A SS-09-15A Mark Thickness Mark Thickness A Th= 1.80 mm N Th= 2.26 mm B Th= 1.85 mm P Th= 2.29 mm C Th= 1.90 mm Q Th= 2.32 mm D Th= 1.95 mm R Th= 2.35 mm E Th= 2.00 mm S Th= 2.40 mm F Th= 2.05 mm T Th= 2.45 mm G Th= 2.08 mm U Th= 2.50 mm H Th= 2.11 mm V Th= 2.55 mm J Th= 2.14 mm W Th= 2.60 mm K Th= 2.17 mm X Th= 2.65 mm L Th= 2.20 mm Y Th= 2.70 mm M Th= 2.23 mm STD 21.71 mm Piston Return Spring Free Length (11) If the preload of counter driven gear does not satisfy the specification, select the adjuster shim from the table below and re- measure the value. Until the valve is within the specification, repeat the procedure.
  67. 67. [ RM-67 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-66A SS-09-17A SS-09-18A SS-09-19A F P D SS-01-83A SST 13. INSTALL 1ST & REVERSE BRAKE (1) Coat 2 new “O” rings with ATF, install them to the 1st & reverse piston. (2) Install the 1st reverse brake piston to the transaxle case. CAUTION: Be careful not to damage the “O” rings of the 1st & reverse brake piston. (3) Install the return spring to the transaxle case. (4) Install the 4 plates, 4 discs and flange. (5) Using SST and a press, install the snap ring. CAUTION: Make sure that the snap ring is installed in the groove of the transaxle case correctly.
  68. 68. [ RM-68 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-09-23A SS-09-68A (4) Install a new spacer to the manual valve lever. (5) Install the manual valve lever shaft and manual valve lever. SS-09-20A SS-01-60A SS-09-22A A 14. CHECK PISTON STROKE OF 1ST & REVERSE BRAKE (1) Using a dial indicator and measuring terminal (SST), measure the 1st & reverse brake piston stroke while applying and releasing compressed air (4.0 kgf/cm2 ). 15. INSTALL MANUAL VALVE LEVER SHAFT (a) Coat a new oil seal with ATF. (b) Install the oil seal to the transaxle case. (3) Install the parking lock rod to the manual valve lever. Piston Stroke 0.791-1.489 mm Oil seal in depth 0.75-1.25 mm
  69. 69. [ RM-69 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-58A SS-09-24A SS-01-56A (6) Using a pin punch and hammer, drive in a new pin. (7) Turn the spacer and lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft. (8) Using a pin punch, stake the spacer through the small hole. (9) Check that the spacer does not turn. (10) Install the manual detent spring with 1 bolt. TT = 7.8-11.8 N.m (80-120 kgf.cm) 16. INSTALL PARKING LOCK PAWL (1) Install the parking lock pawl shaft, torsion spring and parking lock pawl. CAUTION: Check that the edge of torsion spring fits into the groove securely. SS-01-55A SS-09-25A
  70. 70. [ RM-70 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-54A SS-09-26A SST SST (2) Install the parking lock pawl bracket with the 2 bolts. TT = 5.9-8.8 N.m (60-90 kgf.cm) 18. INSTALL PLANETARY RING GEAR HINT: Before installing the planetary ring gear, be sure to replace the planetary ring gear flange of the planetary ring gear with a new one. (1) Using SST and a press, install the planetary ring gear. SS-09-21A SST SST 17. INSTALL COUNTER DRIVE GEAR (1) Using SST and a press, install the counter drive gear. CAUTION: Be careful not to apply excessive force to thee transaxle case.
  71. 71. [ RM-71 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-53A SS-09-29A (3) Install a new nut. (4) Using a small torque wrench, while turning to counter drive gear 100 turn par minute and measure the preload. HINT: When the preload is smaller than the specification, tighten the nut more and adjust the preload. SST SS-01-86C (5) Using SST, lift the transaxle case. SS-09-71A (5) Using a chisel and a hammer, stake the counter drive gear nut New Bearing 0.05-0.35 N.m (0.5-3.6 kgf.cm) Reused Bearing 0.05-0.35 N.m (0.5-3.6 kgf.cm)
  72. 72. [ RM-72 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-09-31A SS-09-32A SS-09-33A LockFreely (2) Coat the planetary carrier thrust washer with petroleum jelly and install it onto the planetary gear. 20. INSTALL NO.2 ONE-WAY CLUTCH (1) Install the No.2 one-way clutch to the transaxle. (2) Check that the planetary gear turns freely counterclockwise and locks clockwise. SS-01-52A (6) Fix the counter drive gear with parking lock pawl. SS-09-30A 19. INSTALL PLANETARY GEAR (1) Install the planetary gear to the transaxle housing.
  73. 73. [ RM-73 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-09-36A SS-09-37A F D P SS-01-48A 22. INSPECT DISC, PLATE AND FLANGE OF 2ND BRAKE (1) Check to see if the sliding surface of the disc, plate and flange are worn or burnt. CAUTION: If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. 23. INSTALL 2ND BRAKE (1) Install the flange, 2 discs and 2 plates. (2) Install the 2nd brake return spring. CAUTION: Make sure that the snap ring is installed in the groove of the transaxle case correctly. (3) Coat 2 new “O” rings with ATF, install them to the 2nd brake piston. SS-09-34A SS-09-35A (3) Install the anti-rattle clip in the place shown in the illustration (the space between the No.2 one-way clutch outer race and transaxle case), push the anti-rattle clip in until you hear the "click". 21. CHECK 2ND BRAKE PISTON RETURN SPRING (1) Using vernier calipers, measure the free length of thee spring together with spring seat.
  74. 74. [ RM-74 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-09-40A SS-01-46A SS-01-83A SST (6) Place SST on the 2nd brake and compress the piston return spring with a press. (7) Using a screwdriver, install thee snap ring. CAUTION: Make sure that the snap ring is installed in the groove of the transaxle case correctly. 24. INSTALL FRONT PLANETARY SUN GEAR (1) Coat the thrust bearing race with petroleum jelly and install it onto the front planetary sun gear. (2) Install the front planetary sun gear to the transaxle case. SS-09-38A SS-09-39A (4) Install the 2nd brake piston into the 2nd brake clutch cylinder. CAUTION: Be careful not to damage to “O” rings. (5) Install the 2nd brake.
  75. 75. [ RM-75 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-42A SS-09-42A SS-09-43A (3) Install the rear planetary sun gear and one- way clutch assembly to the transaxle case. 26. INSTALL FORWARD CLUTCH HUB (1) Coat the thrust bearing race with petroleum jelly and install it onto the transaxle case. CAUTION: Check the direction of race. (2) Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward clutch hub. CAUTION: Check the direction of bearing. SS-01-45A SS-09-41A (2) Coat the thrust bearing race with petroleum jelly and install it onto the rear planetary sun gear and one-way clutch assembly. CAUTION: Check the direction on the bearing. 25. INSTALL REAR PLANETARY SUN GEAR AND ONE-WAY CLUTCH ASSEMBLY (1) Install the thrust washer and one-way clutch assembly to the rear planetary sun gear.
  76. 76. [ RM-76 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-39A SS-09-45A 27. INSTALL FORWARD & REVERSE CLUTCH ASSEMBLY (1) Install the thrust bearing race and thrust needle roller bearing to the forward & reverse clutch assembly. (2) Install the forward & reverse clutch assembly to the transaxle case. SS-01-40A SS-09-44A (3) Install the forward clutch hub to the transaxle case. (4) Coat the thrust bearing race with petroleum jelly and install it onto the forward clutch hub.
  77. 77. [ RM-77 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-09-47A A SS-09-70A P D F (2) Install the flange, 2 discs and 2 plates to the transaxle case. (3) Clean the connected part the transaxle case and transaxle rear cover. (4) As shown in the illustration, place a straight edge on the transaxle case and measure the distance between the 2nd coast & o/d brake flange and straight edge using vernier calipers. (Dimension A) SS-09-16A SS-09-46A 29. INSTALL O/D & 2ND COAST BRAKE FLANGE, DISC AND PLATE (1) Using a screwdriver, install the snap ring to the transaxle case. CAUTION: Make sure that the snap ring is installed in the groove of the transaxle case correctly. 28. INSPECT DISC, PLATE AND FLANGE OF O/D & 2ND COAST BRAKE (1) Check to see if the sliding surface of the disc, plate and flange are worn or burnt. CAUTION: If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs. Before assembly new discs, soak them in ATF for at least 15 minutes.
  78. 78. [ RM-78 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-09-49A SS-09-50A (2) Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward & reverse clutch assembly. (3) Remove any packing material and be careful not to get oil on the contacting surfaces on the transaxle rear cover on transaxle case. (4) Apply FIPG to the transaxle rear cover. (5) As shown in the illustration, place a straight edge on the o/d brake piston and measure the distance between the transaxle rear cover and straight edge using vernier calipers, (Dimension B) (6) Calculate the piston stroke value using the following formula. Select flange which satisfies the piston stroke value and install it. Piston stroke = Dimension A - Dimension B 30. INSTALL TRANSAXLE REAR COVER (1) Install new 4 apply gaskets to the transaxle rear cover. Piston Stroke 0.65-1.05 mm SS-09-48A B SS-01-36A
  79. 79. [ RM-79 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-09-51A SS-09-52A 33. INSTALL DIRECT CLUTCH HUB (1) Install the direct clutch hub to the transaxle case. 34. INSTALL DIRECT CLUTCH (1) Install thee thrust bearing race and thrust needle roller bearing to the transaxle case. SS-01-35A SS-01-34A SS-01-29A 32. INSTALL DIFFERENTIAL GEAR ASSEMBLY (5) Install the transaxle rear cover to the transaxle case with the 9 bolts. TT = 19.6-29.4 N.m (200-300 kgf.cm) 31. INSTALL COUNTER DRIVEN GEAR ASSEMBLY
  80. 80. [ RM-80 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-28A SS-01-27A (3) Install the 6 bolts. TT = 19.6-29.4 N.m (200-300 kgf.cm) 37. MEASURE INPUT SHAFT END PLAY (1) Measure the end play in axial direction. End Play 0.3-0.9 mm (2) Install the direct clutch assembly to the transaxle case. 35. INSTALL NEW APPLY GASKET 36. INSTALL OIL PUMP (1) Install the thrust needle roller bearing to the transaxle case. CAUTION: Check the direction of the bearing. (2) Place the oil pump through the input shaft, and align the bolt holes of the oil pump with the transaxle case. SS-01-31A SS-01-30A SS-09-53A
  81. 81. [ RM-81 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-25A SS-01-24A 40. INSTALL TRANSAXLE WIRE (1) Coat a new “O” ring with ATF install it to the transaxle wire. (2) Install the transaxle wire the to the transaxle case with the 1 bolt. TT = 3.9-6.9 N.m (40-70 kgf.cm) SS-09-54A SS-09-55A SS-09-67A 38. CHECK INPUT SHAFT ROTATION (1) Make sure that the input shaft rotates smoothly. 39. INSTALL TRANSAXLE HOUSING (1) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transaxle case. (2) Apply FIPG to the transaxle housing. (3) Install the transaxle housing to the transaxle case with the 16 bolts. TT = 23.5-35.5 N.m (240-360 kgf.cm) HINT: Apply seal packing or equivalent to the 3 bolts indicated by arrows.
  82. 82. [ RM-82 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-16A SS-01-15A 43. INSTALL BRAKE DRUM GASKET (1) Coat a new brake drum gasket with ATF, install it to the transaxle case. 44. INSTALL CHECK VALVE (1) Install the spring and check valve. SS-01-17A 41. INSTALL ACCUMULATOR PISTON AND SPRING (1) Coat new 6 “O” rings with ATF and install them to the pistons. (2) Coat the 3 springs and 3 accumulator pistons with ATF, install them to the holes. 42. INSTALL APPLY GASKET (1) Coat a new apply gasket with ATF, install it to the transaxle case. Free (mm) Outer (mm) Color C2 Acum. 57.20 17.50 Light Green C1 Acum. 54.70 17.20 Blue B1 Acum. 47.13 16.00 Pink PART NAME SPRING SS-09-56A B1 Acum. C1 Acum. C2 Acum.
  83. 83. [ RM-83 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-13A SS-01-12A (3) Connect the 5 connectors. (4) Install the ATF temperature sensor with clamp and 3 bolts. CAUTION: Make sure that the transaxle wire does not come out from the oil pan installation surface. 46. INSTALL OIL STRAINER (1) Install a new gasket to the oil strainer. SS-09-57A SS-09-69A 20 mm 20 mm 36 mm49 mm 28 mm 28 mm 40 mm (2) Install the transaxle wire connectors and harness to the valve body assembly with the 14 bolts. TT = 9.8-11.8 N.m (100-120 kgf.cm) CAUTION: When installing the valve body to the transaxle case, do not let each of accumulator pistons B1, C1 and C2 incline. When installing the valve body to the transaxle case, do not hold the solenoids. 45. INSTALL VALVE BODY ASSEMBLY (1) Connect the manual valve control rod to the manual valve lever as shown in the illustration.
  84. 84. [ RM-84 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-01-07A SS-01-82A 48. INSTALL INPUT SPEED SENSOR AND NO.1 BREATHER PLUG (1) Install the No.1 breather plug. (2) Install the input speed sensor with the 1 bolt. TT = 3.9-6.9 N.m (40-70 kgf.cm) 49. INSTALL VEHICLE SPEED SENSOR (1) Install the vehicle speed sensor to the transaxle case with the 1 bolt. TT = 5.9-8.8 N.m (60-90 kgf.cm) SS-01-11A SS-09-58A SS-01-09A 47. INSTALL OIL PAN (1) Install the 2 magnets in the oil pan. (2) Install a new gasket to the oil pan and install them to the transaxle case with the 18 bolts. TT = 6.0-7.9 N.m (60-80 kgf.cm) (2) Install the oil strainer to the valve body with the 3 bolts. TT = 7.8-11.8 N.m (80-120 kgf.cm)
  85. 85. [ RM-85 ]INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-09-59A SS-09-60A 53. INSTALL NEUTRAL START SWITCH (1) Install the neutral start switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts. (2) Install a new lock washer and nuts. TT = 4.3-6.5 N.m (44-66 kgf.cm) (3) Temporarily install the control lever. SS-01-80A SS-01-06A SS-01-05A 51. INSTALL SCREW PLUG (1) Coat a new “O” ring with ATF, install it to the screw plug. (2) Install the screw plug to the transaxle case. TT = 5.9-8.8 N.m (60-90 kgf.cm) 52. INSTALL UNION (1) Coat new 2 “O” rings with ATF, install them to the unions. (2) Install the 2 unions to the transaxle case. TT = 19.6-29.4 N.m (200-300 kgf.cm) 50. INSTALL BRACKET (1) Install the bracket to the transaxle case with the 1 bolt. TT = 19.6-29.4 N.m (200-300 kgf.cm)
  86. 86. [ RM-86 ] INSTALLATION OF COMPONENT PARTS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SS-09-64A A Torque Converter Transaxle Housing SS-09-72A (9) Install the control lever, washer and nut. TT = 9.8-14.7 N.m (100-150 kgf.cm) 54. INSTALL TORQUE CONVERTER (1) Install the torque converter. (2) Check the distance of A. A = 11.1 mm CAUTION: If the distance is out of standards, adjust within standartds again. (8) Using a screwdriver, stake the nut with the lock washer. SS-09-63A (4) Remove control lever. (5) Set the SST and inspect that SST pointer align neutral basic line. (6) Align the groove with neutral basic line. (7) Tighten the 2 bolts. TT = 4.3-6.5 N.m (44-66 kgf.cm) SS-09-73A SST SS-09-74A Neutral basic line SST pointer SST
  87. 87. [ RM-87 ]SERVICE SPECIFICATIONS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. SERVICE SPECIFICATIONS GENERAL CLUTCH & BRAKE C1 ( FORWARD CLUTCH) A/T TYPE BASE A/T 1st 2.875 2nd 1.568 3rd 1.000 4th 0.697 Reverse 2.300 Counter 1.019 Differential 3.750 ATF TYPE VOLUME ATF 5.6L (75 degree C) GEAR RATIO 81-40LE 30510-81C008 Esso JWS-3309: ISU DEXRON Ⅲ = 1:1 Clutch / Brake Flange (F) Plate (P) Disc (D) C1 (Forward Clutch) 1 4 4 C2 (Direct Clutch) 1 2 2 C3 (Rear Clutch) 2 1 2 B1 (O/D & 2nd Coast Brake) 1 2 2 B2 (2nd Brake) 1 2 2 B3 (1st & Reverse Brake) 1 4 4 PART NAME SPEC. Piston Stroke 1.30-1.50 mm Pack Clearance 1.30-1.50 mm Flange Thickness Th= 3.0 mm Type Th= 3.1 mm Th= 3.2 mm Th= 3.3 mm Th= 3.4 mm Th= 3.5 mm Th= 3.6 mm STD 24.04 mm Piston Return Spring Free Length
  88. 88. [ RM-88 ] SERVICE SPECIFICATIONS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. C2 ( DIRECT CLUTCH) C3 ( REVERSE CLUTCH) B1 ( O/D & 2ND COAST BRAKE) B2 ( 2ND BRAKE) B3 ( 1ST & REVERSE BRAKE) OIL PUMP PART NAME SPEC. Piston Stroke 0.40-0.70 mm Pack Clearance 0.40-0.70 mm Flange Thickness Th= 3.0 mm Type Th= 3.2 mm Th= 3.4 mm STD 36.04 mm Piston Return Spring Free Length PART NAME SPEC. Piston Stroke 0.86-1.26 mm Pack Clearance 0.4-1.0 mm Flange Thickness Th= 3.0 mm Type Th= 3.2 mm Th= 3.4 mm Th= 3.6 mm PART NAME SPEC. Piston Stroke 0.65-1.05 mm Pack Clearance 0.65-1.05 mm STD 18.99 mm Piston Return Spring Free Length PART NAME SPEC. Piston Stroke 0.395-1.245 mm Pack Clearance 0.395-1.245 mm STD 15.85 mm Piston Return Spring Free Length PART NAME SPEC. Piston Stroke 0.791-1.489 mm Pack Clearance 0.791-1.489 mm STD 21.71 mm Piston Return Spring Free Length PART NAME Body Bush STD. 38.113-38.138 mm MAX 38.188 mm Stator Shaft Bush STD. 18.424-18.450 mm MAX 18.50 mm Body Clearance STD. 0.10-0.17 mm MAX 0.22 mm Tip Clearance Drive STD. 0.07-0.15 mm MAX 0.20 mm Tip Clearance Driven STD. 0.07-0.15 mm MAX 0.20 mm Side Clearance of STD. 0.02-0.05 mm Drive and Driven Gear MAX 0.10 mm SPEC.
  89. 89. [ RM-89 ]SERVICE SPECIFICATIONS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. OIL SEAL PLANETARY GEAR BUSHING SOLENOID T/A HOUSING - T/C BOSS DISTANCE ACCUMULATOR SPRING SPEC. T/AHousing Oil seal in depth 2.6-3.6 mm T/ACase Oil seal in depth 3.8-4.8 mm Manual Shaft Oil seal in depth 0.75-1.25 mm PART NAME PART NAME SPEC. S1 12-16 ohm (20 degree C) S2 11-15 ohm (20 degree C) ST 11-15 ohm (20 degree C) SL 11-15 ohm (20 degree C) SPEC. T/AHousing-T/C Distance 11.1 mm Free (mm) Outer (mm) Color C2 Acum. 57.20 17.50 Light Green C1 Acum. 54.70 17.20 Blue B1 Acum. 47.13 16.00 Pink PART NAME SPRING PART NAME Pla. Gear Bush Fr Mid Rr STD. 30.00-30.026 mm Fr Mid Rr MAX 30.076 mm Pla. FR Sun Fr Rr STD. 21.500-21.526 mm Gear Bush Fr Rr MAX 21.576 mm Pla. RR Sun Fr Rr STD. 21.500-21.526 mm Gear Bush Fr Rr MAX 21.576 mm SPEC.
  90. 90. [ RM-90 ] SERVICE SPECIFICATIONS DAEWOO 81-40LE (30510-81C008) 03/7 (DW-01M-MRM002) © All Rights Copyright AISIN AW CO., LTD. TIGHTENING TORQUE TT (Tightening Torque) Vehicle Speed Sensor M8-25 5.9-8.8 N.m (60-90 kgf.cm) Neutral Start Switch M6-20 4.3-6.5 N.m (44-66 kgf.cm) Neutral Start Switch Nut --- 9.8-14.7 N.m (100-150 kgf.cm) Input Speed Sensor M6-16 3.9-6.9 N.m (40-70 kgf.cm) Union 1/2-20UNF 19.6-29.4 N.m (200-300 kgf.cm) Screw Plug 5/16-24UNF 5.9-8.8 N.m (60-90 kgf.cm) Oil Pan M6-14.5 6.0-7.9 N.m (60-80 kgf.cm) Oil Strainer M6-12 7.8-11.8 N.m (80-120 kgf.cm) Transaxle Wire M6-16 3.9-6.9 N.m (40-70 kgf.cm) T/A Housing - T/A Case M8-60 23.5-35.5 N.m (240-360 kgf.cm) Oil Pump - T/A Case M8-20 19.6-29.4 N.m (200-300 kgf.cm) T/A Case - T/A Rear Cover M8-25 19.6-29.4 N.m (200-300 kgf.cm) Parking Lock Pawl Bracket M6-16 5.9-8.8 N.m (60-90 kgf.cm) Manual Detent Spring M6-16 7.8-11.8 N.m (80-120 kgf.cm) No.1 Transaxle Case Plate M6-12 7.8-11.8 N.m (80-120 kgf.cm) Oil Reservoir Lock Plate M6-12 3.9-6.9 N.m (40-70 kgf.cm) Oil Apply Pipe Clamp M6-12 3.9-6.9 N.m (40-70 kgf.cm) Screw Plug - Rear Cover 5/16-24UNF 5.9-8.8 N.m (60-90 kgf.cm) T/A Housing - Bracket M8-16 19.6-29.4 N.m (200-300 kgf.cm) Stator Shaft - Oil Pump Body M6-16.7 7.8-11.8 N.m (80-120 kgf.cm) 2 M6-20 3 M6-49 1 M6-49 1 M6-36 6 M6-20 5 M6-28 1 M6-40 PART NAME Solenoid - Lower Valve Body Valve Body 1 2 1 1 2 1 18 3 1 16 6 9 2 1 1 3 1 4 1 14 10.0-12.0 N.m (100-200 kgf.cm) 9.8-11.8 N.m (100-120 kgf.cm) 8 5

×