Daewoo 8140le Repair

[ RM-1 ]
FOREWORD
This REPAIR MANUAL covers Disassembly, Inspection and Assembly procedures for the following Automatic Transmission:
Automotic Transmission 81-40LE DAEWOO: 96 484 421 AW: 30510-81C008 Engine Type FAN I 1.5L SOHC REF No.
DW-01M-MRM002
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.
2003
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
DAEWOO 81-40LE (30510-81C008)

All Rights Copyright AISIN AW CO., LTD.
03/7 (DW-01M-MRM002)
[ RM-2 ]
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
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-3 ]
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
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-4 ]
BLANK
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-5 ]
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
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-6 ]
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 DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-7 ]
OPERATION
F1 C1 B2
F2 B3 C2
FR OM T /C
Co u n te r Dr iv e G e a r As s y
C ou n te r Dr iv e n G e a r As s y
C3
B1
Diff e re n tia l Ge a r As s y
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-8 ]
OPERATION
POSITION P R N D 1st 2nd 3rd 3<=>4 4th 2 1st 2nd 3rd L 1st 2nd V<9 V>=11 Solenoid S1 ON ON ON ON ON ON OFF OFF OFF ON ON OFF ON ON S2 ON ON ON ON ON OFF OFF ON ON ON OFF OFF ON OFF ST OFF OFF ON OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF C1 OFF OFF OFF OFF ON ON ON ON<=>OFF OFF ON ON ON ON ON Clutch C2 OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF ON OFF OFF C3 OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF B1 OFF OFF OFF OFF OFF OFF OFF OFF<=>ON ON OFF ON OFF OFF ON Brake B2 OFF OFF OFF OFF OFF ON ON ON ON OFF ON ON OFF ON B3 OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF 1 Way Clutch F1 OFF OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF ON F2 OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF ON OFF
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-9 ]
REPAIR PROCEDURES
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.
GENERAL REPAIR INSTRUCTIONS

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.
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-10 ]
REMOVAL OF COMPONENT PARTS

Clip Breather Hose No.1 Breather Plug
"O" Ring
Bracket Transaxle Revolution Sensor
Speed Sensor
Union
"O" Ring Union
"O" Ring "O" Ring Screw Plug Gasket
SS-01-81A Non Reusable Part
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-11 ]
Oil Seal Apply Gasket Brake Drum Gasket Torque Converter "O" ring
Spacer Valve Body Assembly
Gasket
Oil Seal
Newtral Start Switch "O" ring Gasket
"O" ring "O" ring Non Reusable Part
"O" ring
SS-01-01A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-12 ]
Apply Gasket "O" Ring Forward Clutch & Reverse Clutch Assembly
Transaxle Rear Cover
O/D Brake Piston Rear Planetary Sun Gear One-Way Clutch Assembly
"O" Ring
Forward Clutch Hub
"O" Ring
Front Planetary Sun Gear 2nd Brake Piston
"O" Ring Planetary Gear
1st & Reverse Brake Piston Planetary Ring Gear
Non Reusable Part
SS-01-02A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-13 ]
Counter Driven Gear
Differential Gear
Oil Seal
Counter Drive Gear
Direct Clutch Hub
Nut Direct Clutch Assembly Oil Pump
Apply Gasket
Non Reusable Part

SS-01-03A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-14 ]
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
3. REMOVE UNION (1) Remove the 2 unions. (2) Remove the 2 O rings from the unions.
SS-01-05A
4. REMOVE SCREW PLUG (1) Remove the screw plug from the transaxle case. (2) Remove the O ring from the screw plug.
SS-01-06A
5. REMOVE BRACKET (1) Remove the 1 bolt and bracket.
SS-01-80A
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.
SS-01-07A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
REMOVAL OF COMPONENT PARTS 7. PLACE TRANSAXLE ON WOODEN BLOCKS
[ RM-15 ]
SS-01-08A
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.
SS-01-09A
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.
SS-01-10A
SS-01-11A
(2) Remove the gasket from the oil strainer.
SS-01-12A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-16 ]
REMOVAL OF COMPONENT PARTS 11. REMOVE VALVE BODY ASSEMBLY (1) Remove the bolt and ATF temperature sensor with clamp. (2) Disconnect the 5 connectors.
SS-01-13A
(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.
SS-01-14A
12. REMOVE CHECK VALVE (1) Remove the check valve and spring.
SS-01-15A
13. REMOVE BRAKE DRUM GASKET (1) Remove the brake drum gasket.
SS-01-16A
14. REMOVE APPLY GASKET
SS-01-17A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-17 ]
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
SS-01-18A
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.
(3) Remove the 2 O rings from the C2 accumulator piston.
SS-01-19A
(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
SS-01-20A
the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when air-blowing. (6) Remove the 2 O rings from the C1 accumulator piston.
SS-01-21A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-18 ]
REMOVAL OF COMPONENT PARTS (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
SS-01-22A
to splash ATF when air-blowing. (8) Remove the 2 O rings from the B1 accumulator piston.
SS-01-23A
16. REMOVE TRANSAXLE WIRE (1) Remove the 1 bolt. (2) Remove the transaxle wire from the transaxle case.
SS-01-24A
(3) Remove the O ring from the transaxle wire.
SS-01-25A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-19 ]
17. REMOVE VEHICLE SPEED SENSOR (1) Remove the 1 bolt and the vehicle speed sensor.
SS-01-82A
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
SS-01-26A
transaxle housing is removed. 19. INSPECT INPUT SHAFT END PLAY (1) Using a dial indicator, measure the input shaft end play.
SS-01-27A
20. REMOVE OIL PUMP (1) Remove the 6 bolts and oil pump.
SS-01-28A
21. REMOVE DIFFERENTIAL GEAR ASSEMBLY
SS-01-29A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-20 ]
REMOVAL OF COMPONENT PARTS 22. REMOVE APPLY GASKET
SS-01-30A
23. REMOVE DIRECT CLUTCH ASSEMBLY
SS-01-31A
(1) Remove the direct clutch assembly from the transaxle case. (2) Remove the thrust needle roller bearing from the direct clutch assembly.
SS-01-32A
24. REMOVE DIRECT CLUTCH HUB (1) Remove the direct clutch hub, thrust needle roller bearing and thrust bearing race from the transaxle case.
SS-01-33A
25. REMOVE COUNTER DRIVEN GEAR ASSEMBLY
SS-01-34A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-21 ]
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.
SS-01-35A
27. REMOVE 4 APPLY GASKETS
SS-01-36A
28. REMOVE 2ND COAST & O/D BRAKE FLANGE, DISC AND PLATE (1) Remove the flange, 2 discs and 2 plates from the transaxle case.
SS-01-37A
29. REMOVE FORWARD & REVERSE CLUTCH ASSEMBLY (1) Remove the thrust needle roller bearing and forward & reverse clutch assembly.
SS-01-38A
(2) Remove the thrust needle roller bearing and thrust bearing race from the forward & reverse clutch assembly.
SS-01-39A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-22 ]
REMOVAL OF COMPONENT PARTS 30. REMOVE FORWARD CLUTCH HUB (1) Remove the forward clutch hub from the transaxle case.
SS-01-40A
(2) Remove the thrust bearing race and thrust needle roller bearing from the forward clutch hub.
SS-01-41A
31. REMOVE REAR PLANETARY SUN GEAR AND 1 WAY CLUTCH ASSEMBLY (1) Remove the rear planetary sun gear and 1 way clutch assembly.
SS-01-42A
(2) Remove the thrust bearing race from the rear planetary sun gear and 1 way clutch assembly.
SS-01-43A
(3) Remove the thrust needle roller bearing and planetary carrier thrust washer from the rear planetary sun gear and 1 way clutch assembly.
SS-01-44A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-23 ]
(4) Remove the 1 way clutch assembly and thrust washer from the rear planetary sun gear.
SS-01-45A
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.
SS-01-46A
33. REMOVE 2ND BRAKE (1) Using SST and a press, remove the 2 snap rings, 2ND brake and 2ND brake piston return spring.
SST
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
SS-01-47A
SS-01-83A
using a waste cloth. Take care not to splash ATF when air-blowing. (3) Remove the 2 O rings from the 2nd brake piston.
SS-01-48A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-24 ]
REMOVAL OF COMPONENT PARTS (4) Remove the 2 plates, 2 discs and flange.
SS-01-49A
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.
SS-01-50A
(2) Remove the No.2 one-way clutch from the planetary gear. (3) Remove the anti-rattle clip.
SS-01-51A
35. REMOVE COUNTER DRIVE GEAR AND PLANETARY RING GEAR (1) Fix the counter drive gear with the parking lock pawl.
SS-01-52A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
REMOVAL OF COMPONENT PARTS (2) Using SST, lift the transaxle case.
[ RM-25 ]
SST
SS-01-86C
SST
(3) Using SST and a hammer, unstake the counter drive gear nut.
SS-01-84A
(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.
SS-01-53A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-26 ]
REMOVAL OF COMPONENT PARTS (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.
SS-01-62A
SST SS-01-63C
36. REMOVE PARKING LOCK PAWL (1) Remove the 2 bolts and parking lock pawl bracket.
SS-01-54A
(2) Remove the parking lock pawl shaft, torsion spring and parking lock pawl.
SS-01-55A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-27 ]
37. REMOVE MANUAL VALVE LEVER SHAFT (1) Remove the 1 bolt and manual detent spring.
SS-01-56A
(2) Using a chisel and hammer, unstake and remove the spacer.
SS-01-57A
(3) Using a pin punch and hammer, drive out the pin.
SS-01-58A
(4) Remove the manual valve lever shaft and manual valve lever.
SS-01-59A
(5) Remove the parking lock rod from the manual valve lever.
SS-01-60A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-28 ]
REMOVAL OF COMPONENT PARTS (6) Using a screwdriver, remove the oil seal.
SS-01-61A
38. REMOVE 1ST & REVERSE BRAKE (1) Using SST and a press, remove the snap ring.
SST
SS-01-83A
(2) Remove the flange, 4 plates, 4 discs and return spring.
SS-01-64A
(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
SS-01-65A
using a waste cloth. Take care not to splash ATF when air-blowing. (4) Remove the 2 O rings from the 1st & reverse brake piston.
SS-01-66A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-29 ]
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
40. REMOVE OUTER TAPERED ROLLER BEARING RACE AND SHIM FROM TRANSAXLE CASE
SST
(1) Using SST, remove the outer tapered roller bearing race and shim.
SS-01-68A
41. REMOVE OIL RESERVOIR LOCK PLATE (1) Remove the 3 bolts and oil reservoir lock plate from the transxle housing.
SS-01-70A
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.
SS-01-71A
43. REMOVE OIL SEAL (1) Using SST and a hammer, remove the oil seal from the transaxle housing.
SST
SS-01-72A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-30 ]
REMOVAL OF COMPONENT PARTS 44. REMOVE OIL SEAL OF TRANSAXLE HOUSING (1) Using SST and a hammer, remove the oil seal.
SST SS-01-73A
SST
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,
SS-01-85A
preventing the O/D brake piston from being deformed. (2) Remove the O/D brake return spring.
SS-01-75A
(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
SS-01-76A
to splash ATF when air-blowing. (4) Remove the 2 O rings from the O/D brake piston.
SS-01-77A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-31 ]
46. DISASSEMBLE TRANSAXLE REAR COVER (1) Remove the 2 seal rings from the transaxle rear cover. CAUTION: Do not expand the seal ring excessively.
SS-01-78A
(2) Remove the 4 screw plugs and 4 O rings from the transaxle rear cover.
SS-01-79A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-32 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 1. OIL PUMP

Stator Shaft
Oil Pump Body
Oil Pump Drive Gear Oil Pump Drive Gear
SS-02-01A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-33 ]
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.
SS-02-02A
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.
SS-02-03A
3. REMOVE OIL PUMP DRiVE GEAR AND DRIVEN GEAR
SS-02-04A
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.
Body Clearance
SS-02-05A
STD. MAX
0.10-0.17 mm 0.22 mm
2. CHECK TIP CLEARANCE OF DRIVEN GEAR (1) Measure the tip clearance between the driven gear teeth and drive gear teeth.
Tip Clearance Driven STD. MAX 0.07-0.15 mm 0.20 mm
SS-02-06A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-34 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 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.
Side Clearance of Drive and Driven Gear
Gear Thickness Type Mark 1 2 3 4 5 Mark 1 2 3 4 5
SS-02-07A
STD. MAX
0.02-0.05 mm 0.10 mm
Drive Gear Th= 8.440-8.449 mm Th= 8.450-8.459 mm Th= 8.460-8.470 mm Th= 8.471-8.480 mm Th= 8.481-8.490 mm Driven Gear Th= 8.440-8.449 mm Th= 8.450-8.459 mm Th= 8.460-8.470 mm Th= 8.471-8.480 mm Th= 8.481-8.490 mm
4. CHECK OIL PUMP BODY BUSHING (1) Using a dial indicator, measure the inside diameter of the oil pump body bushing.
Body Bush STD. 38.113-38.138 mm MAX 38.188 mm
SS-02-08A
5. CHECK STATOR SHAFT BUSHING (1) Using a dial indicator, measure the inside diameter of the stator shaft bushings.
Stator Shaft Bush STD. 18.424-18.450 mm MAX 18.50 mm
SS-02-09A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-35 ]
ASSEMBLY OF OIL PUMP

1. INSTALL OIL PUMP DRIVE GEAR AND DRIVEN GEAR
SS-02-04A
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)
SS-02-03A
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.
SS-02-02A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-36 ]
2. DIRECT CLUTCH
Return Spring "O" Ring "O" Ring Input Shaft Sub-assembly
Snap Ring Seal Ring
Piston Disc
Snap Ring Flange
Plate
Non Reusable Part SS-03-01A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DISASSEMBLY OF DIRECT CLUTCH
[ RM-37 ]
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
SS-03-02A
releasing compressed air (4.0 kgf/cm2).
Piston Stroke
0.40-0.70 mm
2. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring.
SS-03-03A
3. REMOVE FLANGE, DISC AND PLATE (1) Remove the flange, 2 discs and 2 plates.
SS-03-04A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-38 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 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.
SST
SS-03-05A
(3) Remove the direct clutch return spring.
SS-03-06A
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
SS-03-07A
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.
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-39 ]
6. REMOVE O RING (1) Using a small screwdriver, remove the O ring from the direct clutch piston.
SS-03-08A
(2) Remove the O ring from the input shaft.
SS-03-09A
7. REMOVE SEAL RING (1) Remove the 2 seal rings from the input shaft. CAUTION: Do not expand the ring ends excessively.
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
SS-03-11A
number is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. 2. CHECK DIRECT CLUTCH RETURN SPRING (1) Using vernier calipers, measure the free length of the spring together with the spring sheet.
Piston Return Spring Free Length

SS-03-12A
STD 36.04 mm
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-40 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 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.
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
2. INSTALL O-RING (1) Coat a new O ring with ATF, and install the O ring to the input shaft.
SS-03-09A
(2) Coat a new O ring with ATF, and install the O ring to the direct clutch piston.
SS-03-08A
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-03-14A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-41 ]
4. INSTALL DIRECT CLUTCH RETURN SPRING. (1) Install the direct clutch return spring.
SS-03-06A
(2) Place SST on the return spring and

SST
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,
SS-03-05A
preventing the piston return spring from being deformed. Do not expand the snap ring excessively.
5. INSTALL PLATE, DISC AND FLANGE

F D
(1) Install the 2 plates, 2 discs and flange. HINT: Before installing the discs, coat them with ATF.
SS-03-15A
(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-03-03A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-42 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 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).
Piston Stroke
SS-03-02A
0.40-0.70 mm
HINT: If the piston stroke is out of standards, select another flange.
Flange Thickness Type
Th= 3.0 mm Th= 3.2 mm Th= 3.4 mm
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-43 ]
3. PLANETARY RING GEAR
Planetary Ring Gear
Snap Ring
Planetary Ring Gear Flange
Non Reusable Part SS-04-01A
DISASSEMBLY OF PLANETARY RING GEAR DISASSEMBLY OF PLANETARY RING GEAR 1. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring.
SS-04-02A
2. REMOVE PLANETARY RING GEAR FLANGE (1) Remove the planetary ring gear flange from the planetary ring gear.
SS-04-03A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-44 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 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-04-03A
2. INSTALL SNAP RING (2) Using a screwdriver, install the snap ring.
SS-04-02A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-45 ]
4. 1 WAY CLUTCH
2nd Brake Hub
Retainer
Snap Ring
1 Way Clutch SS-05-01A
Freely
DISASSEMBLY OF 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
Lock
SS-05-02A
counterclockwise. 2. REMOVE SNAP RING (1) Using a screwdriver, remove the snap ring.
SS-05-03A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-46 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 3. REMOVE 1 WAY CLUTCH
SS-05-04A
4. REMOVE RETAINER (1) Using a small screwdriver, remove the retainer.
SS-05-05A
ASSEMBLY OF 1 WAY CLUTCH 1. INSTALL RETAINER (1) Install the retainer to the 2nd brake hub. HINT: Install the retainer closely.
2. INSTALL 1 WAY CLUTCH
SS-05-04A
3. INSTALL SNAP RING (1) Using a screwdriver, install the snap ring.
SS-05-03A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS Freely
[ RM-47 ]
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.
Lock
SS-05-02A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-48 ]
5. FORWARD AND REVERSE CLUTCH
Flange
Disc Flange Snap Ring
Plate
Plate
Disc Flange Snap Ring Snap Ring Seal Ring "O" Ring "O" Ring Forward Clutch Piston Forward Clutch Return Spring Clutch Balancer Non Reusable Part SS-06-01C Forward Clutch Drum Intermediate Shaft Sub-assembly
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS DISASSEMBLY OF FORWARD AND
[ RM-49 ]
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.
SS-06-02A
(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
SST
2. CHECK PISTON STROKE OF FORWARD CLUTCH

SST
(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
Piston Stroke 1.30-1.50 mm 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.
SS-06-04A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-50 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 4. REMOVE FLANGE, DISC AND PLATE (1) Remove the 2 flanges, 2 discs and plate from the reverse clutch drum.
SS-06-05A
SS-06-06A
6. REMOVE FLANGE, DISC AND PLATE (1) Remove the flange, 4 discs and 4 plates from the forward clutch drum.
SS-06-07A
SST
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-06-19A
SS-06-08A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-51 ]
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
SS-06-09A
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
SS-06-10A
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-06-11A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-52 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS (2) Using a small screwdriver, remove the O ring from the intermediate shaft subassembly.
SS-06-12A
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
SS-06-13A
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.
SS-06-14A
STD 24.04 mm
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
(2) Coat a new O ring with ATF, and install it to the forward clutch drum.
SS-06-11A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-53 ]
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.
SS-06-15A
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.
SS-06-16A
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.
SS-06-08A
SST
(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-06-19A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-54 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS 5. INSTALL PLATE, DISC AND FLANGE
P F
(1) Install the 4 plates, 4 discs and flange.
D
SS-06-18A
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.
SS-06-06A
F D P D F SS-06-17A
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-06-04A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-55 ]
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
SS-06-02A
releasing compressed air (4.0 kgf/cm2). Piston Stroke 0.86-1.26 mm HINT: If the piston stroke is out of standards, select another flange.
Th= 3.0 mm Th= 3.2 mm Th= 3.4 mm Th= 3.6 mm
SST
10. CHECK PISTON STROKE OF FORWARD CLUTCH

SST
(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
Piston Stroke 1.30-1.50 mm HINT: If the piston stroke is out of standards, select another flange.
Th= 3.0 mm Th= 3.1 mm Th= 3.2 mm Th= 3.3 mm Th= 3.4 mm Th= 3.5 mm Th= 3.6 mm
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.
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-56 ]
6. COUNTER DRIVEN GEAR
Outer Tapered Roller Bearing Race
Outer Tapered Roller Bearing Race
Counter Driven Gear SS-07-01A
DISASSEMBLY OF COUNTER DRIVEN GEAR 1. REMOVE FRONT DRIVE PINION REAR

SST
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.
SS-07-02C
(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
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-57 ]
2. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (1) Using SST and a press, remove the front
SST
drive pinion tapered roller bearing front inner race from the differential drive pinion.
SS-07-04C
(2) Using SST, remove the front drive pinion tapered roller bearing front outer race from the transaxle housing.
SS-07-05C
3. REMOVE SIFFERENTIAL DRIVEN PINION PLUG (1) Using extension bar and hammer, remove the differential drive pinion plug.
SS-07-06C
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.
Pinion plug
SS-07-07C
2.3-2.8 mm
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.
SST
SS-07-08C
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-58 ]
ASSEMBLY AND DISASSEMBLY OF COMPONENT PARTS (2) Using SST and a hammer, install the front drive pinion tapered roller bearing front outer race to the transaxle housing.
SST SS-07-09C
3. INSTALL COUNTER DRIVE GEAR (1) Using SST and a press, install the counter drive gear to the differential drive pinion.
SST
SS-07-10C
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
SST
to the differential drive pinion.
SS-07-11C
(2) Using SST and a hammer, install the pinion washer and front drive pinion tapered roller bearing rear outer race to the transaxle case.
SST SS-07-12C
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-59 ]
7. VALVE BODY
SS-08-17A
SL Solenoid
DISASSEMBLY OF VALVE BODY 1. REMOVE SHIFT SOLENOID (NO.1, NO.2, ST, SL) (1) Remove the each bolt and the solenoids.
No.2 Solenoid No.1 Solenoid ST Solenoid SS-11-01AM
SL Solenoid (28 mm, 49mm)
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 =
No.2 Solenoid (20 mm, 49 mm) No.1 Solenoid (20 mm, 49 mm) ST Solenoid (20 mm) SS-11-04AM
10.0-12.0 N.m (100-200 kgf.cm)
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-60 ]
8. DIFFERENTIAL
Differential Assembly Side Bearing Outer Race
Side Bearing Outer Race
SS-10-01A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
INSTALLATION OF COMPONENT PARTS
[ RM-61 ]

RACE AND BEARING SPECIFICATIONS
C B
F G
SS-09-01A
(mm) A RASE Outer Dia. --(Front) Inner Dia. --BEARING Outer Dia. 62.00 Inner Dia. 43.20 RACE Outer Dia. --(REAR) Inner Dia. ---
B 30.60 19.30 29.60 18.10 28.20 18.10
C 45.50 34.95 46.50 33.30 -----
D ----57.50 42.50 -----
E 29.00 19.30 ---------
F ----48.50 32.50 or 32.90 -----
G ----30.20 17.80 32.60 20.50
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-62 ]
INSTALLATION OF COMPONENT PARTS 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)
SS-01-79A
(3) Install the 2 seal rings to the transaxle rear cover.
SS-01-78A
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.

SS-09-02A
STD 18.99 mm
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.
SS-01-77A
(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-09-03A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-63 ]
(3) Using SST and a press, install the O/D &

SST
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
SS-01-85A
brake piston from being deformed. 4. INSTALL TRANSAXLE HOUSING OIL SEAL (1) Using SST and a hammer, drive in a new oil
SST SST
seal.
Oil seal in depth
2.6-3.6 mm
SS-09-05A
SST
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-09-07A
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 =
SS-01-71A
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-01-70A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-64 ]
INSTALLATION OF COMPONENT PARTS 8. INSTALL TRANSAXLE CASE OIL SEAL (1) Using SST and a hammer, drive in a new oil seal.
SST SST
Oil seal in depth
3.8-4.8 mm
SS-09-09A
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)
SS-01-67A
10. ADJUST COUNTER DRIVEN GEAR PRELOAD (1) Install the differential gear to the transaxle case.
SS-09-11A
(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)
SS-01-26A
(4) Using a SST, turn the differential gear assembly right and left 2 or 3 times to allow the bearing settle.
SS-09-12A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-65 ]
(5) Using SST and small torque wrench, measure the preload of the differential gear. HINT: Note down the measured valve.
SS-09-13A
(6) Remove the transaxle housing and install the counter driven gear.
SS-09-14A
(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)
SS-01-26A
9) Using a SST, turn the differential gear assembly right and left 2 or 3 times to allow the bearing settle.
SS-09-12A
(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 Reused Bearing
SS-09-13A
0.78-13.7 N.m (8.0-14.0 kgf.cm) 0.39-0.69 N.m (4.0-7.0 kgf.cm)
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-66 ]
INSTALLATION OF COMPONENT PARTS (11) If the preload of counter driven gear does not satisfy the specification, select the adjuster shim from the table below and remeasure the value. Until the valve is within the specification, repeat the procedure. 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.
Mark A B C D E F G H J K L M
Thickness Th= 1.80 mm Th= 1.85 mm Th= 1.90 mm Th= 1.95 mm Th= 2.00 mm Th= 2.05 mm Th= 2.08 mm Th= 2.11 mm Th= 2.14 mm Th= 2.17 mm Th= 2.20 mm Th= 2.23 mm
Mark N P Q R S T U V W X Y
Thickness Th= 2.26 mm Th= 2.29 mm Th= 2.32 mm Th= 2.35 mm Th= 2.40 mm Th= 2.45 mm Th= 2.50 mm Th= 2.55 mm Th= 2.60 mm Th= 2.65 mm Th= 2.70 mm
11. CHECK 1ST & REVERSE BRAKE PISTON RETURN SPRING (1) Using vernier calipers, measure the free length of the spring together with spring seat.

SS-09-15A
STD 21.71 mm
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
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-67 ]
13. INSTALL 1ST & REVERSE BRAKE (1) Coat 2 new O rings with ATF, install them to the 1st & reverse piston.
SS-01-66A
(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.
SS-09-17A
(3) Install the return spring to the transaxle case.
SS-09-18A
(4) Install the 4 plates, 4 discs and flange.

D
SS-09-19A
(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.
SST
SS-01-83A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-68 ]
INSTALLATION OF COMPONENT PARTS 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).
Piston Stroke
SS-09-20A
0.791-1.489 mm
15. INSTALL MANUAL VALVE LEVER SHAFT (a) Coat a new oil seal with ATF. (b) Install the oil seal to the transaxle case.
Oil seal in depth
0.75-1.25 mm
SS-09-22A
(3) Install the parking lock rod to the manual valve lever.
SS-01-60A
(4) Install a new spacer to the manual valve lever.
SS-09-23A
(5) Install the manual valve lever shaft and manual valve lever.
SS-09-68A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-69 ]
(6) Using a pin punch and hammer, drive in a new pin.
SS-01-58A
(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.
SS-09-24A
(10) Install the manual detent spring with 1 bolt. TT =
7.8-11.8 N.m (80-120 kgf.cm)
SS-01-56A
16. INSTALL PARKING LOCK PAWL (1) Install the parking lock pawl shaft, torsion spring and parking lock pawl.
SS-01-55A
CAUTION: Check that the edge of torsion spring fits into the groove securely.
SS-09-25A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-70 ]
INSTALLATION OF COMPONENT PARTS (2) Install the parking lock pawl bracket with the 2 bolts. TT =
5.9-8.8 N.m (60-90 kgf.cm)
SS-01-54A
17. INSTALL COUNTER DRIVE GEAR (1) Using SST and a press, install the counter drive gear. CAUTION: Be careful not to apply excessive
SST
force to thee transaxle case.
SST
SS-09-21A
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.
SST
SST
SS-09-26A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
INSTALLATION OF COMPONENT PARTS (3) Install a new nut.
[ RM-71 ]
SS-01-53A
(4) Using a small torque wrench, while turning to counter drive gear 100 turn par minute and measure the preload.
New Bearing Reused Bearing 0.05-0.35 N.m (0.5-3.6 kgf.cm) 0.05-0.35 N.m (0.5-3.6 kgf.cm)
HINT: When the preload is smaller than the

SS-09-29A
specification, tighten the nut more and adjust the preload. (5) Using SST, lift the transaxle case.
SST
SS-01-86C
(5) Using a chisel and a hammer, stake the counter drive gear nut
SS-09-71A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-72 ]
INSTALLATION OF COMPONENT PARTS (6) Fix the counter drive gear with parking lock pawl.
SS-01-52A
19. INSTALL PLANETARY GEAR (1) Install the planetary gear to the transaxle housing.
SS-09-30A
(2) Coat the planetary carrier thrust washer with petroleum jelly and install it onto the planetary gear.
SS-09-31A
20. INSTALL NO.2 ONE-WAY CLUTCH (1) Install the No.2 one-way clutch to the transaxle.
SS-09-32A
(2) Check that the planetary gear turns freely counterclockwise and locks clockwise.
Freely
Lock
SS-09-33A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-73 ]
(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".
SS-09-34A
21. CHECK 2ND BRAKE PISTON RETURN SPRING (1) Using vernier calipers, measure the free length of thee spring together with spring seat.
SS-09-35A
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
SS-09-36A
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.
F P
D SS-09-37A
(3) Coat 2 new O rings with ATF, install them to the 2nd brake piston.
SS-01-48A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-74 ]
INSTALLATION OF COMPONENT PARTS (4) Install the 2nd brake piston into the 2nd brake clutch cylinder. CAUTION: Be careful not to damage to O rings.
SS-09-38A
(5) Install the 2nd brake.
SS-09-39A
(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
SST
installed in the groove of the transaxle case correctly.
SS-01-83A
24. INSTALL FRONT PLANETARY SUN GEAR (1) Coat the thrust bearing race with petroleum jelly and install it onto the front planetary sun gear.
SS-09-40A
(2) Install the front planetary sun gear to the transaxle case.
SS-01-46A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-75 ]
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.
SS-01-45A
(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.
SS-09-41A
(3) Install the rear planetary sun gear and oneway clutch assembly to the transaxle case.
SS-01-42A
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.
SS-09-42A
(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-09-43A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-76 ]
INSTALLATION OF COMPONENT PARTS (3) Install the forward clutch hub to the transaxle case.
SS-01-40A
(4) Coat the thrust bearing race with petroleum jelly and install it onto the forward clutch hub.
SS-09-44A
27. INSTALL FORWARD & REVERSE CLUTCH ASSEMBLY (1) Install the thrust bearing race and thrust needle roller bearing to the forward & reverse clutch assembly.
SS-01-39A
(2) Install the forward & reverse clutch assembly to the transaxle case.
SS-09-45A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-77 ]
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
SS-09-16A
discs. Before assembly new discs, soak them in ATF for at least 15 minutes.
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.
SS-09-46A
(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.
SS-09-70A
(4) As shown in the illustration, place a straight edge on the transaxle case and measure the
A
distance between the 2nd coast & o/d brake flange and straight edge using vernier calipers. (Dimension A)
SS-09-47A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-78 ]
INSTALLATION OF COMPONENT PARTS (5) As shown in the illustration, place a straight edge on the o/d brake piston and measure the distance between the transaxle rear
B
cover and straight edge using vernier calipers, (Dimension B) (6) Calculate the piston stroke value using the following formula. Select flange which
SS-09-48A
satisfies the piston stroke value and install it. Piston stroke = Dimension A - Dimension B Piston Stroke 0.65-1.05 mm
30. INSTALL TRANSAXLE REAR COVER (1) Install new 4 apply gaskets to the transaxle rear cover.
SS-01-36A
(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.
SS-09-49A
(4) Apply FIPG to the transaxle rear cover.
SS-09-50A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-79 ]
(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)
SS-01-35A
31. INSTALL COUNTER DRIVEN GEAR ASSEMBLY
SS-01-34A
32. INSTALL DIFFERENTIAL GEAR ASSEMBLY
SS-01-29A
33. INSTALL DIRECT CLUTCH HUB (1) Install the direct clutch hub to the transaxle case.
SS-09-51A
34. INSTALL DIRECT CLUTCH (1) Install thee thrust bearing race and thrust needle roller bearing to the transaxle case.
SS-09-52A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-80 ]
INSTALLATION OF COMPONENT PARTS (2) Install the direct clutch assembly to the transaxle case.
SS-01-31A
35. INSTALL NEW APPLY GASKET
SS-01-30A
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-09-53A
(3) Install the 6 bolts. TT =
19.6-29.4 N.m (200-300 kgf.cm)
SS-01-28A
37. MEASURE INPUT SHAFT END PLAY (1) Measure the end play in axial direction.
End Play 0.3-0.9 mm
SS-01-27A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
INSTALLATION OF COMPONENT PARTS 38. CHECK INPUT SHAFT ROTATION
[ RM-81 ]
(1) Make sure that the input shaft rotates smoothly.
SS-09-54A
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.
SS-09-55A
(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.
SS-09-67A
40. INSTALL TRANSAXLE WIRE (1) Coat a new O ring with ATF install it to the transaxle wire.
SS-01-25A
(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-01-24A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-82 ]
INSTALLATION OF COMPONENT PARTS 41. INSTALL ACCUMULATOR PISTON AND SPRING (1) Coat new 6 O rings with ATF and install
B1 Acum.
them to the pistons. (2) Coat the 3 springs and 3 accumulator pistons with ATF, install them to the holes.
PART NAME SPRING Free (mm) Outer (mm) Color 57.20 17.50 Light Green 54.70 17.20 Blue 47.13 16.00 Pink
C1 Acum.
C2 Acum. C1 Acum. B1 Acum.
C2 Acum.
SS-09-56A
42. INSTALL APPLY GASKET (1) Coat a new apply gasket with ATF, install it to the transaxle case.
SS-01-17A
43. INSTALL BRAKE DRUM GASKET (1) Coat a new brake drum gasket with ATF, install it to the transaxle case.
SS-01-16A
44. INSTALL CHECK VALVE (1) Install the spring and check valve.
SS-01-15A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-83 ]
45. INSTALL VALVE BODY ASSEMBLY (1) Connect the manual valve control rod to the manual valve lever as shown in the illustration.
SS-09-57A
40 mm 28 mm
20 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)
28 mm 49 mm 36 mm
20 mm SS-09-69A
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.
(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.
SS-01-13A
46. INSTALL OIL STRAINER (1) Install a new gasket to the oil strainer.
SS-01-12A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-84 ]
INSTALLATION OF COMPONENT PARTS (2) Install the oil strainer to the valve body with the 3 bolts. TT =
7.8-11.8 N.m (80-120 kgf.cm)
SS-01-11A
47. INSTALL OIL PAN (1) Install the 2 magnets in the oil pan.
SS-09-58A
(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)
SS-01-09A
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)
SS-01-07A
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-01-82A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
INSTALLATION OF COMPONENT PARTS 50. INSTALL BRACKET
[ RM-85 ]
(1) Install the bracket to the transaxle case with the 1 bolt. TT =
19.6-29.4 N.m (200-300 kgf.cm)
SS-01-80A
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)
SS-01-06A
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)
SS-01-05A
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 =
SS-09-59A
4.3-6.5 N.m (44-66 kgf.cm)
(3) Temporarily install the control lever.
SS-09-60A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-86 ]
INSTALLATION OF COMPONENT PARTS (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. SST
SS-09-73A
TT =
4.3-6.5 N.m (44-66 kgf.cm)
Neutral basic line SST pointer
SST
SS-09-74A
(8) Using a screwdriver, stake the nut with the lock washer.
SS-09-63A
(9) Install the control lever, washer and nut. TT =
9.8-14.7 N.m (100-150 kgf.cm)
SS-09-64A
Transaxle Housing
54. INSTALL TORQUE CONVERTER (1) Install the torque converter.

A
(2) Check the distance of A. A=
11.1 mm
Torque Converter
CAUTION: If the distance is out of standards, adjust within standartds again.
SS-09-72A
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
SERVICE SPECIFICATIONS
[ RM-87 ]
GENERAL
A/T TYPE BASE A/T 81-40LE 30510-81C008 1st 2.875 2nd 1.568 3rd 1.000 4th 0.697 Reverse 2.300 Counter 1.019 Differential 3.750 Esso JWS-3309: ISU DEXRON = 1:1 5.6L (75 degree C)
GEAR RATIO
ATF TYPE VOLUME ATF
CLUTCH & BRAKE

Clutch / Brake C1 (Forward Clutch) C2 (Direct Clutch) C3 (Rear Clutch) B1 (O/D & 2nd Coast Brake) B2 (2nd Brake) B3 (1st & Reverse Brake) Flange (F) 1 1 2 1 1 1 Plate (P) 4 2 1 2 2 4 Disc (D) 4 2 2 2 2 4
C1 ( FORWARD CLUTCH)
PART NAME Piston Stroke Pack Clearance Flange Thickness Type SPEC. 1.30-1.50 mm 1.30-1.50 mm Th= 3.0 mm 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
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-88 ]
C2 ( DIRECT CLUTCH)
PART NAME Piston Stroke Pack Clearance Flange Thickness Type Piston Return Spring Free Length SPEC. 0.40-0.70 mm 0.40-0.70 mm Th= 3.0 mm Th= 3.2 mm Th= 3.4 mm STD 36.04 mm
C3 ( REVERSE CLUTCH)
PART NAME Piston Stroke Pack Clearance Flange Thickness Type SPEC. 0.86-1.26 mm 0.4-1.0 mm Th= 3.0 mm Th= 3.2 mm Th= 3.4 mm Th= 3.6 mm
B1 ( O/D & 2ND COAST BRAKE)

PART NAME Piston Stroke Pack Clearance Piston Return Spring Free Length SPEC. 0.65-1.05 mm 0.65-1.05 mm STD 18.99 mm
B2 ( 2ND BRAKE)
B3 ( 1ST & REVERSE BRAKE)

OIL PUMP
PART NAME Body Bush Stator Shaft Bush Body Clearance Tip Clearance Drive Tip Clearance Driven Side Clearance of Drive and Driven Gear SPEC. STD. 38.113-38.138 mm MAX 38.188 mm STD. 18.424-18.450 mm MAX 18.50 mm STD. 0.10-0.17 mm MAX 0.22 mm STD. 0.07-0.15 mm MAX 0.20 mm STD. 0.07-0.15 mm MAX 0.20 mm STD. 0.02-0.05 mm MAX 0.10 mm
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-89 ]
OIL SEAL
PART NAME T/A Housing T/A Case Manual Shaft Oil seal in depth Oil seal in depth Oil seal in depth SPEC. 2.6-3.6 mm 3.8-4.8 mm 0.75-1.25 mm
PLANETARY GEAR BUSHING

PART NAME Pla. Gear Bush Pla. FR Sun Gear Bush Pla. RR Sun Gear Bush SPEC. Fr Mid Rr STD. Fr Mid Rr MAX Fr Rr STD. Fr Rr MAX Fr Rr STD. Fr Rr MAX 30.00-30.026 mm 30.076 mm 21.500-21.526 mm 21.576 mm 21.500-21.526 mm 21.576 mm
SOLENOID
PART NAME S1 S2 ST SL SPEC. 12-16 ohm (20 degree C) 11-15 ohm (20 degree C) 11-15 ohm (20 degree C) 11-15 ohm (20 degree C)
T/A HOUSING - T/C BOSS DISTANCE

SPEC. T/A Housing-T/C Distance 11.1 mm
ACCUMULATOR SPRING
PART NAME C2 Acum. C1 Acum. B1 Acum. SPRING Free (mm) Outer (mm) 57.20 54.70 47.13 17.50 17.20 16.00 Color Light Green Blue Pink
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)
[ RM-90 ]
TIGHTENING TORQUE
PART NAME Vehicle Speed Sensor Neutral Start Switch Neutral Start Switch Nut Input Speed Sensor Union Screw Plug Oil Pan Oil Strainer Transaxle Wire T/A Housing - T/A Case Oil Pump - T/A Case T/A Case - T/A Rear Cover Parking Lock Pawl Bracket Manual Detent Spring No.1 Transaxle Case Plate Oil Reservoir Lock Plate Oil Apply Pipe Clamp Screw Plug - Rear Cover T/A Housing - Bracket Stator Shaft - Oil Pump Body Solenoid - Lower Valve Body 1 2 1 1 2 1 18 3 1 16 6 9 2 1 1 3 1 4 1 8 2 5 3 1 1 14 6 5 1 M8-25 M6-20 --M6-16 1/2-20UNF 5/16-24UNF M6-14.5 M6-12 M6-16 M8-60 M8-20 M8-25 M6-16 M6-16 M6-12 M6-12 M6-12 5/16-24UNF M8-16 M6-16.7 M6-20 M6-49 M6-49 M6-36 M6-20 M6-28 M6-40 TT (Tightening Torque) 5.9-8.8 N.m (60-90 kgf.cm) 4.3-6.5 N.m (44-66 kgf.cm) 9.8-14.7 N.m (100-150 kgf.cm) 3.9-6.9 N.m (40-70 kgf.cm) 19.6-29.4 N.m (200-300 kgf.cm) 5.9-8.8 N.m (60-90 kgf.cm) 6.0-7.9 N.m (60-80 kgf.cm) 7.8-11.8 N.m (80-120 kgf.cm) 3.9-6.9 N.m (40-70 kgf.cm) 23.5-35.5 N.m (240-360 kgf.cm) 19.6-29.4 N.m (200-300 kgf.cm) 19.6-29.4 N.m (200-300 kgf.cm) 5.9-8.8 N.m (60-90 kgf.cm) 7.8-11.8 N.m (80-120 kgf.cm) 7.8-11.8 N.m (80-120 kgf.cm) 3.9-6.9 N.m (40-70 kgf.cm) 3.9-6.9 N.m (40-70 kgf.cm) 5.9-8.8 N.m (60-90 kgf.cm) 19.6-29.4 N.m (200-300 kgf.cm) 7.8-11.8 N.m (80-120 kgf.cm) 10.0-12.0 N.m (100-200 kgf.cm)
Valve Body
9.8-11.8 N.m (100-120 kgf.cm)
DAEWOO 81-40LE (30510-81C008)

03/7 (DW-01M-MRM002)

Daewoo 8140le Repair

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Daewoo 8140le Repair

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[ RM-1 ]

QUALITY ASSURANCE DEPT.

DAEWOO 81-40LE (30510-81C008)

DAEWOO 81-40LE (30510-81C008)

DAEWOO 81-40LE (30510-81C008)

DAEWOO 81-40LE (30510-81C008)

INSTALLATION OF COMPONENT PARTS....................................... RM-61 SERVICE SPECIFICATIONS ............................................................. RM-87

DAEWOO 81-40LE (30510-81C008)

AW 81-40LE DAEWOO 81-40LE (30510-81C008)

DAEWOO 81-40LE (30510-81C008)

DAEWOO 81-40LE (30510-81C008)

GENERAL REPAIR INSTRUCTIONS

DAEWOO 81-40LE (30510-81C008)

REMOVAL OF COMPONENT PARTS

REMOVAL OF COMPONENT PARTS

Bracket Transaxle Revolution Sensor

"O" Ring Union

"O" Ring "O" Ring Screw Plug Gasket

SS-01-81A Non Reusable Part

DAEWOO 81-40LE (30510-81C008)

REMOVAL OF COMPONENT PARTS

Spacer Valve Body Assembly

Newtral Start Switch "O" ring Gasket

"O" ring "O" ring Non Reusable Part

DAEWOO 81-40LE (30510-81C008)

REMOVAL OF COMPONENT PARTS

Transaxle Rear Cover

Forward Clutch Hub

Front Planetary Sun Gear 2nd Brake Piston

"O" Ring Planetary Gear

1st & Reverse Brake Piston Planetary Ring Gear

Non Reusable Part

DAEWOO 81-40LE (30510-81C008)

REMOVAL OF COMPONENT PARTS

Counter Driven Gear

Counter Drive Gear

Direct Clutch Hub

Nut Direct Clutch Assembly Oil Pump

Non Reusable Part

DAEWOO 81-40LE (30510-81C008)

REMOVAL OF COMPONENT PARTS

SEPARATE EXTERNAL PARTS

5. REMOVE BRACKET (1) Remove the 1 bolt and bracket.

DAEWOO 81-40LE (30510-81C008)

REMOVAL OF COMPONENT PARTS 7. PLACE TRANSAXLE ON WOODEN BLOCKS

(2) Remove the gasket from the oil strainer.

DAEWOO 81-40LE (30510-81C008)

14. REMOVE APPLY GASKET

DAEWOO 81-40LE (30510-81C008)

REMOVAL OF COMPONENT PARTS

(3) Remove the 2 O rings from the C2 accumulator piston.

DAEWOO 81-40LE (30510-81C008)

(3) Remove the O ring from the transaxle wire.

DAEWOO 81-40LE (30510-81C008)

REMOVAL OF COMPONENT PARTS

21. REMOVE DIFFERENTIAL GEAR ASSEMBLY

DAEWOO 81-40LE (30510-81C008)

REMOVAL OF COMPONENT PARTS 22. REMOVE APPLY GASKET

23. REMOVE DIRECT CLUTCH ASSEMBLY

25. REMOVE COUNTER DRIVEN GEAR ASSEMBLY

DAEWOO 81-40LE (30510-81C008)

REMOVAL OF COMPONENT PARTS

27. REMOVE 4 APPLY GASKETS