> Dismantling and assemblage of some transmission knots. Daewoo Matiz (since 1997 of release)
Daewoo Matiz since 1997 of release
1. The general data
2. Maintenance service
3. The engine
4. Transmission
4.1. Coupling
4.2. A transmission and differential
4.2.1. The design description
4.2.2. Possible malfunctions of a transmission and methods of their elimination
4.2.3. Removal and transmission installation
4.2.4. Removal and installation of elements of a transmission
4.2.5. Dismantling and transmission assemblage
4.2.6. Dismantling and assemblage of some transmission knots
4.3. Drive shaft
5. A running gear
6. A steering
7. Brake system
8. Systems of heating, ventilation and air-conditioning
9. A body electric equipment
10. A body
11. Schemes электроборудования
 







4-2-6-razborka-i-sborka-ryada-uzlov-korobki-peredach.html

4.2.6. Dismantling and assemblage of some transmission knots

Primary shaft of a transmission
Dismantling

Fig. 4.79. Details of primary and secondary shaft: 1 — a lock ring of a primary shaft; 2 — a gear ring of the synchronizer of the fifth transfer; 3 — муфта the synchronizer of the fifth transfer; 4 — a spring of the synchronizer of the fifth transfer; 5 — a synchronizer cracker; 6 — a nave of the synchronizer of the fifth transfer; 7 — a gear ring of the synchronizer of the fifth transfer; 8 — a gear wheel of the fifth transfer of a primary shaft; 9 — the bearing of the fifth transfer of a primary shaft; 10 — the plug of a gear wheel of the fifth transfer of a primary shaft; 11 — the left bearing of a primary shaft; 12 — a gear wheel of the fourth transfer of a primary shaft; 13 — a cogwheel of the synchronizer of the fourth transfer; 14 — the bearing of the fourth transfer of a primary shaft; 15 — муфта the synchronizer of 3-4 transfers; 16 — a spring of the synchronizer of 3-4 transfers; 17 — a cracker of the synchronizer of 3-4 transfers; 18 — a nave of the synchronizer of 3-4 transfers; 19 — a cogwheel of the synchronizer of the third transfer; 20 — a gear wheel of the third transfer of a primary shaft; 21 — the bearing of the third transfer of a primary shaft; 22 — a primary shaft; 23 — the right bearing of a primary shaft; 24 — an epiploon of a primary shaft; 25 — a bolt of fastening of a shaft of a gear wheel of a reverse gear; 26 — a shaft of a gear wheel of a reverse gear; 27 — a reverse gear gear wheel; 28 — a nut of a secondary shaft; 29 — a gear wheel of the fifth transfer of a secondary shaft; 30 — an adjusting lining of the bearing of a secondary shaft; 31 — the left bearing of a secondary shaft; 32 — a gear wheel of the fourth transfer of a secondary shaft; 33 — the plug of gear wheels of 3-4 transfers of a secondary shaft; 34 — a gear wheel of the third transfer of a secondary shaft; 35 — a gear wheel of the second transfer of a secondary shaft; 36 — a cogwheel of the synchronizer of the second transfer; 37 — the bearing of a gear wheel of the second transfer of a secondary shaft; 38 — a lock ring of the synchronizer of 1-2 transfers; 39 — муфта the synchronizer of 1-2 transfers; 40 — a spring of the synchronizer of 1-2 transfers; 41 — a cracker of the synchronizer of 1-2 transfers; 42 — a nave of the synchronizer of 1-2 transfers; 43 — a cogwheel of the synchronizer of the first transfer; 44 — a gear wheel of the first transfer of a secondary shaft; 45 — the bearing of the first transfer of a secondary shaft; 46 — a secondary shaft; 47 — the right bearing of a secondary shaft




Details of primary and secondary shaft are resulted on fig. 4.79.
Remove a transmission.

Fig. 4.80. Use of adaptation DW09921-57810 for removal of the right bearing (1) primary shaft




Arrange the right bearing of 1 primary shaft on stripper DW09921—57810 and remove it (fig. 4.80).

Fig. 4.81. Use of adaptation DW09921-57810 for removal of the plug (1), the left bearing (2) and gear wheels of the fifth transfer (3)




Arrange a gear wheel of the fifth transfer on bearing DW09921-57810 stripper, выпрессуйте a shaft and remove the plug 1 (fig. 4.81) gear wheels of the fifth transfer, the left bearing 2 and a gear wheel of the fifth transfer 3.
Remove the bearing of a gear wheel of the fourth transfer.

Fig. 4.82. Removal of a gear ring and a wave spring of the synchronizer of the fourth transfer




Remove a gear ring and a wave spring of the synchronizer of the fourth transfer (fig. 4.82).

Fig. 4.83. Removal of a lock ring of the synchronizer of the third-fourth transfers




Remove a lock ring of the synchronizer of the third-fourth transfers (fig. 4.83).

Fig. 4.84. Use of adaptation DW09921-57810 for removal of a nave (1) synchronizers of the third-fourth transfers in gathering and gear wheels of the third transfer and a gear ring of the synchronizer (2)




Arrange a gear wheel of the fifth transfer on bearing DW09921-57810 stripper, выпрессуйте a shaft and remove a nave 1 (fig. 4.84) the synchronizer of the third-fourth transfers in gathering and a gear wheel of the third transfer and a gear ring of the synchronizer 2.
Disassemble a nave of the third-fourth transfers in a following order:

Fig. 4.85. Removal of a nave (1) third-fourth transfers, муфты the synchronizer and a cracker (2) and springs of the synchronizer (3)




- Remove a nave 1 (fig. 4.85);
- Remove муфту the synchronizer and a cracker 2;
- Remove springs of the synchronizer 3.

Fig. 4.86. Removal of the bearing (1) gear wheels of the third transfer of a primary shaft




Remove the bearing 1 (fig. 4.86) gear wheels of the third transfer of a primary shaft.

Fig. 4.87. Backlash measurement between a gear ring of the synchronizer with a gear wheel




Combine a gear ring of the synchronizer with a gear wheel and measure a backlash as is shown in fig. 4.87. Rating value of a backlash of 1,0 mm, maximum permissible value — 0,5 mm. If the measured size less maximum permissible, replace a gear ring of the synchronizer.
Check up cone combination. At abnormal work of the synchronizer connection between an internal surface of a gear ring and a cone is considered partially defective despite a correct backlash between a gear wheel and a gear ring. Therefore the cone and an internal surface of a gear ring should be checked up. The internal surface of a gear ring should be smooth. A surface of black colour the abnormal; if check difficult, execute check after drawing of lead minium. The cone can have wavy deterioration.

Fig. 4.88. Places of measurement of width of a groove of a cracker of a gear ring of the synchronizer




Check up width of a groove of a cracker of a gear ring of the synchronizer (fig. 4.88). Nominal and maximum permissible sizes of width are resulted in tab. 4.8. If the width exceeds maximum permissible size, replace a gear ring of the synchronizer.
Check up deterioration of a gear ring of the synchronizer, if necessary, replace it.

Table 4.8     of Size of width of a groove of a cracker of a gear ring of the synchronizer
Gear wheel
Width of a groove of a cracker, mm

The nominal
Maximum permissible
1st transfers
8,2
8,6
2nd, 3rd, 4th transfers
9,6
10,0
5th transfers
9,4
9,8


Fig. 4.89. Crackers (1) and springs (2) synchronizers




Check up on absence of deterioration a cracker of the synchronizer 1 (fig. 4.89).
Check up on absence of easing, damages or breakage of a spring 2.
Assemblage

Fig. 4.90. Installation of the bearing (1) gear wheels of the third transfer and a gear ring (2) synchronizers of the third transfer




Apply a thin film трансмиссионного oils and establish the bearing 1 (fig. 4.90) gear wheels of the third transfer and a gear ring 2 synchronizers of the third transfer.
Collect a nave of the synchronizer of the third-fourth transfers in a following order:
- Establish synchronizer springs in a nave;

Fig. 4.91. Installation of a nave of the synchronizer of the third-fourth transfer: 1 — a nave; 2 — муфта; And and In — выступание a spring and a synchronizer cracker




- Establish a synchronizer cracker. In case of assemblage муфты the synchronizer and a nave, observance of condition А=В (fig. 4.91) is necessary;
- Establish a nave 1 in муфту 2.

Fig. 4.92. Use of a hammer and tool DW09940-53111 for installation of a nave of the synchronizer of the third-fourth transfers in gathering (1) on a primary shaft




Using a hammer and tool DW 09940—53111, establish a nave of the synchronizer of the third-fourth transfers in gathering 1 (fig. 4.92) on a primary shaft.
Arrange the longest part of a flange of a nave in a direction to a gear wheel of the third transfer and combine a cracker and a flute on a gear ring. At repressing gear wheel teeths can be damaged.
Establish a lock ring of the synchronizer of the third-fourth transfers (fig. 4.83 see). Combine a flute on a gear ring with a cracker of a nave and establish a gear ring of the synchronizer of the fourth transfer and a wave spring.

Fig. 4.93. Installation on a primary shaft of the bearing (1) and gear wheels (2) fourth transfers




Establish the bearing 1 (fig. 4.93) the fourth transfer of a primary shaft and a gear wheel 2 fourth transfers.

Fig. 4.94. Installation on a primary shaft of the plug of a gear wheel of the fifth transfer (1) and the left bearing (2) primary shaft




Using a hammer and tool DW 09925—98221, establish on a shaft the plug of a gear wheel of the fifth transfer 1 (fig. 4.94) and the left bearing 2 primary shaft.

Fig. 4.95. Installation on a primary shaft of the right bearing (1)




Using a hammer and tool DW 09925—9822, establish on a shaft the right bearing 1 (fig. 4.95).
Establish the gear mechanism.
Secondary shaft of a transmission
Dismantling
Remove the gear mechanism.

Fig. 4.96. Use of adaptation DW 09921—57810 for removal of the left bearing (1) secondary shaft and gear wheels of the fifth transfer (2)




Remove the right bearing of a secondary shaft. Arrange a gear wheel of the fifth transfer on adaptation DW 09921—57810 and выпрессуйте the left bearing 1 (fig. 4.96) a secondary shaft and a gear wheel of the fifth transfer 2.
Remove the plug of the third-fourth transfers of a secondary shaft.

Fig. 4.97. Use of adaptation DW 09921—57810 for removal of a gear wheel by the third (1) and the second (2) transfers




Arrange a gear wheel of the fifth transfer on adaptation DW 09921—57810 and выпрессуйте gear wheels of the third 1 (fig. 4.97) and the second 2 transfers.
Remove the bearing of a gear wheel of the second transfer of a secondary shaft.
Remove a cogwheel of a gear wheel of the second transfer.

Fig. 4.98. Removal of a lock ring of the synchronizer of transfers by the first-second




Remove a lock ring of the synchronizer of the first-second of transfers (fig. 4.98).

Fig. 4.99. Use of adaptation DW 09921—57810 for removal of a nave of the synchronizer in gathering (1) and gear wheels of the first transfer / a gear ring of the synchronizer of the first transfer (2)




Arrange a gear wheel of the fifth transfer on adaptation DW 09921—57810 and выпрессуйте a synchronizer nave in gathering 1 (fig. 4.99) and a gear wheel of the first transfer / a gear ring of the synchronizer of the first transfer 2.
Remove a gear ring of the synchronizer of the first transfer from a gear wheel of the first transfer.
Disassemble a nave of the first-second of transfers in a following order:

Fig. 4.100. Removal of a nave (1) the first-second transfers, муфты the synchronizer and a cracker (2) and springs of the synchronizer (3)




- Remove a nave 1 (fig. 4.100);
- Remove муфту the synchronizer and a cracker 2;
- Remove springs of the synchronizer 3.

Fig. 4.101. Removal of the bearing of the first transfer of a secondary shaft




Remove the bearing of the first transfer of a secondary shaft (fig. 4.101).
Check up муфту for inadequate work after assemblage of a nave and муфты.
Check up on absence of deterioration a nave and муфту.
Assemblage

Fig. 4.102. Installation on a secondary shaft of the bearing (1) gear wheels of the first transfer, a gear wheel (2) first transfers and a cogwheel of the synchronizer (3) first transfers




Put a layer трансмиссионного oils and establish on a secondary shaft the bearing 1 (fig. 4.102) gear wheels of the first transfer, a gear wheel 2 first transfers and a cogwheel of the synchronizer 3 first transfers.

Fig. 4.103. Width of a flute for a cracker: And = 8,2 mm — the first gear ring of the synchronizer; In = 9,6 mm — the second gear ring of the synchronizer




Be cautious, as there is a difference in width of a flute for a cracker between the first and the second gear rings of the synchronizer (fig. 4.103). The width of a flute for a cracker of the first gear ring of the synchronizer is equal 8,2 mm, and for the second gear ring of the synchronizer — 9,6 mm.
Collect a nave of the synchronizer of the first-second transfer in a following order:
- Establish synchronizer springs in a nave;

Fig. 4.104. Installation of a nave of the synchronizer of the first-second transfer: 1 — a nave; 2 — муфта; And and In — выступание a spring and a synchronizer cracker




- Establish a synchronizer cracker. In case of assemblage муфты the synchronizer and a nave, observance of condition А=В (fig. 4.104) is necessary;
- Establish a nave 1 in муфту 2.

Fig. 4.105. Use of tools DW09940-53111 and КМ466—А for installation of a nave of the synchronizer of transfers by the first-second to gathering (1) on a secondary shaft




Using tools DW 09940 53111 and КМ466—А, establish a nave of the synchronizer of the first-second of transfers in gathering 1 (fig. 4.105) on a secondary shaft. Arrange a synchronizer cracker in a flute of a gear ring of the synchronizer.
Establish the second cogwheel, having combined the second cogwheel with a cracker.
Establish a lock ring of the synchronizer first-second gear rings (fig. 4.98 see).

Fig. 4.106. Installation on a secondary shaft of the bearing (1) and gear wheels (2) second transfers




Establish the bearing 1 (fig. 4.106) and a gear wheel 2 second transfers.

Fig. 4.107. Use of a hammer and tool DW09913-80112 for installation of the plug of gear wheels of the fourth-fifth transfers (1) and gear wheels of the third transfer (2)




Using a hammer and tool DW 09913—80112, establish on a secondary shaft the plug of gear wheels of the fourth-fifth transfers 1 (fig. 4.107) and a gear wheel of the third transfer 2.

Fig. 4.108. Use of a hammer and tool DW09925-98221 for installation on a secondary shaft of a gear wheel of the fourth transfer (1)




Using a hammer and tool DW 09925—98221, establish on a secondary shaft a gear wheel of the fourth transfer 1 (fig. 4.108).

Fig. 4.109. Use of a hammer and tool DW09925-98221 for installation of the left bearing (1) on a secondary shaft




Using a hammer and tool DW 09913—80112, establish the left bearing 1 (fig. 4.109) on a secondary shaft.
Establish the right bearing on a secondary shaft.
Establish the gear mechanism.
Gear change plugs
Dismantling

Fig. 4.110. Gear change plugs: 1 — a gear change shaft in gathering; 2 — a bolt of blocking of switching; 3 — the gear change lever; 4 — the lever of a choice of transfers in gathering; 5 — пыльник a gear change shaft; 6 — the mechanism of management of a gear change; 7 — a directing bolt of switching; 8 — a directing plate of the mechanism of management of a gear change; 9 — a lining of the mechanism of management of a gear change; 10 — a plug of switching of the first-second of transfers; 11 — a shaft of switching of the first-second of transfers; 12 — a ball/spring of a shaft of switching of the first-second of transfers; 13 — a cam of switching of the first-second of transfers; 14 — a cam of switching of the third-fourth transfers; 15 — a ball/spring of a shaft of switching of the third-fourth transfers; 16 — a shaft of switching of the third-fourth transfers; 17 — a plug of switching of the third-fourth transfers; 18 — the lever of switching of a reverse gear; 19 — a ball fifth/back transfers; 20 — a ball/spring of a shaft of switching by a heel / back transfers; 21 — directing a ball/spring of a shaft of switching of a reverse gear; 22 — a shaft of switching fifth/back transfers; 23 — a cam of switching by a heel / back transfers; 24 — a directing ball of a plug of switching of the fifth transfer; 25 — a plug of switching of the fifth transfer; 26 — the lever of switching of a reverse gear




Gear change plugs are shown on fig. 4.110.
Remove the gear mechanism.
Remove each shaft of switching in gathering from the gear mechanism.
Disassemble a shaft of switching of the first-second of transfers in a following order:
- Fix a shaft of switching of the first-second of transfers in gathering in a vice with soft sponges;

Fig. 4.111. Use of a hammer and a chisel for removal of a finger of a plug of switching of transfers by the first-second




- Hammer and chisel beat out a finger (fig. 4.111) plugs of switching of the first-second of transfers;

Fig. 4.112. An arrangement of a finger (1) plugs of switching of the first-second of transfers (2) and a finger (3) cams of switching of a gear wheel of the first-second of transfers (4)




- Remove a plug 2 (fig. 4.112) switchings of a gear wheel of transfers by the first-second;
- A hammer and a chisel beat out a finger 3 cams of switching of a gear wheel of the first-second of transfers;
- Remove a cam of 4 switchings of a gear wheel of the first-second of transfers.
Disassemble a shaft of switching of the third-fourth transfers in gathering in a following order:
- Fix a shaft of switching of the third-fourth transfers in gathering in a vice with soft sponges;

Fig. 4.113. An arrangement of a finger (1) plugs of switching of the third-fourth transfers (2) and a finger (3) cams of switching of a gear wheel of the third-fourth transfers (4)




- A hammer and a chisel beat out a finger 1 (fig. 4.113) plugs of switching of the third-fourth transfers;
- Remove a plug of switching of the third-fourth transfers 2;
- A hammer and a chisel beat out a finger 3 (fig. 4.113 see) cam of switching of the third-fourth transfers;
- Remove a plug of switching of the third-fourth transfers 4.
Disassemble a shaft of switching fifth-back transfers to gathering in a following order:

Fig. 4.114. Removal of a shaft of switching (1) and a ball (2) gear wheels fifth-back transfers and a directing ball and a spring (3) switchings of a reverse gear




- Press and remove a shaft of switching without a cam 1 (fig. 4.114);
- Remove a ball of 2 gear wheels fifth-back transfers both directing ball and a spring of 3 switchings of a reverse gear;
- Fix a switching shaft in a vice with soft sponges;

Fig. 4.115. An arrangement of a finger (1) cams of switching of a reverse gear (2) and a finger (4) cams of switching of the fifth transfer (3)




- A hammer and a chisel beat out a finger 1 (fig. 4.115) a cam of switching of a reverse gear;
- Remove a cam of 2 switchings of a reverse gear;
- A hammer and a chisel beat out a finger 4 cams of switching of the fifth transfer;
- Remove a cam of 3 switchings of the fifth transfer.
Check up on absence of a bend, deformation or damage of a shaft of switching and, if necessary, replace a shaft.

Fig. 4.116. Measurement of a thickness of the end of a plug of switching




Measure a thickness of the end of a plug of switching (fig. 4.116). Nominal and maximum permissible sizes of a thickness of the end of a plug of switching are resulted in tab. 4.9. If width below maximum permissible size, replace a plug.

Table 4.9    of the Thickness of the end of a plug of switching
Switching plug
Thickness of the end of a plug of switching, mm

The nominal
Maximum permissible
The first-second transfer
8,7
8,1
The third-fourth transfer
7,8
7,2
The fifth transfer
7,8
7,2

Assemblage
Assemblage of plugs of a gear change spend to sequences, return to removal. At assemblage establish new fingers of fastening of plugs and cams.
Differential
Dismantling

Fig. 4.117. Details of differential and картера transmissions: 1 — a conducted gear wheel of a speedometer; 2 — a stopper for check of level of oil; 3 — the left lining; 4 — a cover картера; 5 — the switch of a lantern of a backing; 6 — right картер transmissions; 7 — a plate; 8 — left картер transmissions; 9 — a stopper oil plum; 10 — a plate with a flute for oil; 11 — a plate lateral; 12 — a lateral cover; 13 — a differential cogwheel; 14 — the left epiploon of differential; 15 — the left bearing of differential; 16 — картер differential; 17 — a gear wheel of a drive of a speedometer; 18 — the left bearing of differential; 19 — the right epiploon of differential; 20 — a finger of a shaft of a gear wheel of differential; 21 — an adjusting lining of the satellite; 22 — the satellite; 23 — a shaft of a gear wheel of differential; 24 — a differential gear wheel; 25 — a washer of a gear wheel of differential




Details of differential and картера transmissions are shown on fig. 4.117.
Remove differential in gathering.
Remove a differential cogwheel in a following order:
- Fix differential in gathering in a vice with soft sponges;

Fig. 4.118. An arrangement of bolts (1) fastenings of a cogwheel of differential (2)




- Turn out bolts 1 (fig. 4.118);
- Remove a cogwheel 2.

Fig. 4.119. Use of a hammer and a chisel for выбивания a finger of a gear wheel of differential




Hammer and chisel beat out a finger of a gear wheel of differential (fig. 4.119).

Fig. 4.120. Extraction of a shaft (1) from a differential box




Take a shaft 1 (fig. 4.120) from a differential box.
Remove gear wheels and satellites in a following order:

Fig. 4.121. An arrangement of a gear wheel and a washer (1), satellites (2) and adjusting linings (3) satellites




- Rotating the satellite, remove gear wheels and washers 1 (fig. 4.121);
- Remove satellites 2;
- Remove adjusting linings 3 from satellites.

Fig. 4.122. Use of stripper DW 220—020А—01 and the holder of the bearing of differential DW220—020А—02 for removal of the right bearing of differential and a gear wheel of a drive of a speedometer (1)




Using stripper DW220—020А—01 and the holder of the bearing of differential DW220—020А—02, remove the right bearing of differential and a gear wheel of a drive of a speedometer 1 (fig. 4.122).

Fig. 4.123. Use of stripper DW 220—020А—01 and the holder of the bearing of differential DW 220—020А—03 for removal of the left bearing of differential (1)




Using stripper DW220—020А—01 and the holder of the bearing of differential DW220—020А—03, remove the left bearing of differential 1 (fig. 4.123).

Fig. 4.124. Measurement люфта a lateral support of differential on an axis of the satellite (1)




Measure люфт a lateral support of differential on an axis of the satellite 1 (fig. 4.124). Rating value люфта 0,05 mm, maximum permissible value — 0,33 mm. If люфт exceeds maximum permissible value, replace the satellite.
Check up on absence of deterioration or задиров an adjusting lining of a support.
Assemblage
Put a layer трансмиссионного oils on internal details: the bearing, a washer, an adjusting lining etc.

Fig. 4.125. Use of the tool 09913—76010 and a hammer for installation of the left bearing (1) differentials




Using the tool 09913—76010 and a hammer, establish the left bearing 1 (fig. 4.125) differential.

Fig. 4.126. Use of the tool 09913—76010 and a hammer for installation of a gear wheel of a drive of a speedometer (1) and the right bearing of differential (2)




Using the tool 09913—76010 and a hammer, establish a gear wheel of a drive of a speedometer 1 (fig. 4.126) and the right bearing of differential 2.
Establish satellites and gear wheels in a following order:
- Enter an adjusting lining of a support into satellites;

Fig. 4.127. Installation in a box of differential of satellites (1) and gear wheels and washers (2)




- Establish satellites 1 (fig. 4.127);
- Establish gear wheels and washers 2.
Establish a finger and a gear wheel shaft in a following order:

Fig. 4.128. Installation of a shaft (1) in an aperture of a gear wheel and a place an arrangement of a finger (2)




- Rotating, establish a shaft 1 (fig. 4.128) in a gear wheel aperture;
- Chisel and hammer запрессуйте a new finger 2.
Fix a differential box in a vice with soft sponges.

Fig. 4.129. An arrangement of bolts of fastening of a cogwheel (1) differentials




Establish a cogwheel 1 (fig. 4.129) and fix bolts, having tightened their moment 80—100 Нм.
Establish differential in gathering.


To return back
4.2.5. Dismantling and transmission assemblage
On the following page
4.3. Drive shaft