Signs of a broken Daewoo Nexia gearbox
Manual transmission diagram
The Daewoo Nexia gearbox diagram shows the presence of shafts, a cover, and an intermediate housing. The drive includes control levers, brackets, rods, and support. The choice of speed on Nexia is provided by the scenes. This component is a system of interconnected levers. Replacing the rocker is necessary if the gears begin to work poorly or if there is an extraneous sound when the lever moves. In some cases, adjusting the gearbox rocker can solve the problem.
Repair of the gearbox is necessary if the owner of the vehicle begins to notice difficulty engaging the gear. As a rule, this is the result of wear and tear on components related to the gearbox. A grinding noise when shifting gears may be a result of an out-of-adjustment clutch.
The Nexia gearbox will quickly become unusable if there is insufficient oil level in the box. As a rule, the result of this is deterioration in the management of a foreign car. In this case, a comprehensive diagnosis of the machine is necessary, which can be ordered at any specialized service center.
Wear of the backstage. Diagnostics and what is needed for replacement
Clear and precise gear shifts in any engine operating mode can give way to clunky shifts with delays after a mileage of 190-220 thousand This is especially true for second, fourth and reverse gears.
As a rule, the gear selection mechanism in the box itself has nothing to do with this. In 90% of cases, the cause of unclear gear shifting is the rocker and gear selection rod , which wear out first.
Wear of the gear selection mechanism itself is only possible if the transmission oil change regulations are not followed, or if the wrong oil is used.
The transmission oil in the F16 Nexia gearbox is changed every 90-100 thousand kilometers. The oil recommended by the factory is synthetic with a class of at least GL4 with a viscosity of SAE 80W. For replacement you need about 1.8 liters.
In general, the following symptoms will indicate wear and tear of the gear shift rod:
Gear shift lever play .
Second and reverse gears are difficult to engage
The gears do not start the first time .
When switching, you hear extraneous noises and the crunching of synchronizers.
To replace and repair the gear shift mechanism, the following spare parts from the Daewoo Nexia catalog will be needed:
gear selector cover gasket , Nexia catalog number 96298951 ;
gear shift rod fork clamp, no.94535807;
gear shift rod oil seal 90129204 , dimensions 13x26x7 mm;
gearbox linkage rod - 94580787;
two latches for the switching mechanism, no. 94580787;
You can also buy an assembled rocker on Nexia .
The repair technology may differ depending on the wear of certain spare parts of the Daewoo Nexia backstage, but the general algorithm is as follows.
Daewoo Nexia - choice of gearbox oil
75w90 GL-4
What gear oil should I use? Daewoo Nexia car owners are recommended to choose a fluid with the following characteristics: SAE 80W class GL-4. In some cases, the use of 75W-90 fuel is allowed, since it has high protective properties and helps to extend the life of the high-speed gearbox. The frequency of checking the level of fuel and lubricating fluid is prescribed every 15,000 km. The box requires about 2 liters.
Important! When changing the oil, a new pan gasket is required. This spare part is responsible for sealing the crankcase. Transmission gaskets differ in the number of holes available. This must be taken into account when the component is purchased.
Disassembling the gearbox and final drive - Maintenance and repair manual for Daewoo Nexia
5th gear driven gear 60, synchronizer gear coupling 58 and 5th gear synchronizer hub To replace the Daewoo Nexia clutch, we carry out the following procedure. The weight of a manual gearbox is about 60 kg.
To repair the gearbox mechanism on a Nexia (for example, to replace synchronizers, forks, bearings), it is not necessary to remove the gearbox...
Having unscrewed the fastening bolts, we move the clutch slave cylinder along with the bracket without disconnecting the hydraulic drive line. This circumstance allows you to freely use the work, while respecting personal non-property rights - the right of authorship, the right to a name, the right to protection from any distortion and the right to protect the author's reputation - since these rights are protected indefinitely.
At the same time, in order to avoid leakage of working fluid from the clutch hydraulic reservoir, we pinch the clutch hydraulic hose. Remove the left mudguard from the engine compartment. Remove the front wheel drives.
Before unscrewing the bolts securing the clutch housing to the engine cylinder block, mark their location. This will simplify the subsequent installation of the gearbox, since the bolts have different diameters and rod lengths.
repair of the Daewoo Nexia gearbox (part 2)
At the top, the clutch housing is attached to the cylinder block with three bolts. For clarity, we show the location of the bolts for the upper fastening of the clutch housing on the dismantled power unit.
I also recommend that the repair of the gear shift drive be carried out in parallel with the replacement of the rod and oil seal of the gear shift mechanism.
You can read how to do this here. So, in most cases, the rod lugs have a fairly large bore, as an example of a large bore - photo 3.
As a result, it is better to replace the gear shift rod. We've sorted out the spare parts... Let's move on to the tool.
Removing the gear shift drive from the car: In the engine compartment, loosen the bolt on the clamp connecting the gear shift shaft and drive photo 5. Pull out the spring clip and pull out the small axis connecting the gear shift rod to the drive photo 6 and 7.
We take out the axle connecting the gear shift drive to the bracket photo 8. To facilitate subsequent assembly, we use a marker to apply installation marks that determine the relative position of the parts on the connection of the gearbox control rod. Using a 12mm spanner, loosen the tightening of the coupling bolt of the transmission control rod.
We remove the inner part of the connection. Using a 14 mm socket wrench with a ratchet, unscrew the 3 bolts securing the flywheel protective casing to the gearbox housing.
Do-it-yourself repair of the Daewoo Nexia brake cylinder
Disconnect the flywheel protective cover. We place a support in the form of a hydraulic jack and a wooden block under the gearbox.
Using a 14 mm socket wrench with a ratchet and an extension, unscrew the 3 bolts securing the bracket for the left power unit support to the gearbox housing. If the switch malfunctions, unscrew it and replace it with a working one by installing a new sealing washer.
If during replacement some of the oil leaked out of the box, bring its level to normal. Replacing the input shaft oil seal It is impossible to replace the oil seal without disassembling the gearbox, since the clutch release bearing guide sleeve is pressed into the housing and is removed inside the box.
Due to these considerations, it is better to entrust the oil seal replacement to specialists. Automotive products Advertising Website design and development After the expiration of copyright, in Russia this period is equal to three years, the work becomes public domain.
Checkpoint on the Daewoo Nexia - what will we use?
When purchasing oil, pay attention to the release date.
Despite the fact that the manufacturer declares the indefinite use of gear oil in the Daewoo Nexia gearbox, it needs to be changed.
Experts advise not to exceed the mileage before an oil change of 100-120 thousand km . Otherwise, there will be expensive repairs - synchronizers, seals, shafts will not last long on old oil.
Oil Standards
In the event of a forced oil change, the plant itself recommends using fluids of the SAE 80W , class not lower than GL-4 . In cases where the vehicle is operated in low temperature conditions, the recommended viscosity should correspond to the standard 75W-90 GL-4 .
The plant does not give clear recommendations regarding the composition of the oil, although initially it pours mainly mineral oils into the gearbox. The only advantage of mineral oils for gearboxes is the price.
Types and manufacturers
Otherwise, synthetic and semi-synthetic fluids work much better. This affects both the lubricating and washing properties of the oil and its durability. According to experts, the brand does not play a special role, although each driver has his own preferences. Castrol Syntrans 75w90 is perfect for Nexia .
Self-replacement of the shift link on a Daewoo Nexia car
The tools you will need are: Do-it-yourself replacement of the rocker in a Daewoo Nexia car Removing the rocker. Do some prep work. Replace the bushings and rubber seals of the drive lever. Once everything is assembled, you can begin installation.
Take your time tightening the clamp that connects the shaft to the rocker.
Assembling and adjusting the scenes. Assembly is carried out in the reverse order of disassembly. The drawstring was secured in the center using a rod with latches.
The best video
Place the gearshift lever in neutral. Moving on to the engine compartment, on the right side of the rod that goes into the box, you need to feel the plastic plug.
Pull it out and place a drill in the resulting hole. With one hand, take the rod from the gearbox and turn it all the way towards you, facing the car, this will happen in a clockwise direction. There is no need to unscrew everything. Carefully engaging 4th gear and asking a friend to hold the helicopter, we disengage it.
Next, we take out the cotter pin that connects the second edge of the helicopter with the switch rod in the box. Then the fun begins.
Replacing the rocker in a Daewoo Nexia car with your own hands
Your task is to remove the helicopter. It is attached with a pin between two pads. And secured on top with a spring plate. If the car is already many years old.
Analysis of the gearbox mechanism on the Nexia - Daewoo Nexia FAQ
Place the stop under the gearbox and unscrew the two bolts securing the left power unit support to the side member, see Fig.
repair of the Daewoo Nexia gearbox (part 1)
Press the clutch pedal several times and listen to the sound of the gearbox bearings.
Find a quality car service near your home! All service stations are certified according to GOST-R.
Laping Laping is caused by small abrasive particles of scale, sand, corundum, etc.
The gearbox weighs more than 30 kg, so work with an assistant or using an adjustable stop or lifting device. Often, malfunctions of the clutch and mechanical daewoo nexia gearbox repair manifest themselves in difficulty shifting gears, an increase in force on the shift lever, the shock nature of the shift, the grinding of gears or the gear switching off on its own.
Disconnect the wiring harness connectors from the reverse light switch and the vehicle speed sensor.
Remove the gear shift mechanism drive. Remove the front wheel drives. Drain the oil from the gearbox.
Using a 10 mm wrench, unscrew the two bolts securing the coolant pump pipe and move the pipe slightly upward.
Using a 19 mm wrench, unscrew the upper bolt securing the gearbox and the clutch slave cylinder bracket to the engine cylinder block. Using a 19 mm wrench, we hold the bolt from turning, and with a second wrench of the same size, we unscrew the nut of the bolt securing the clutch slave cylinder bracket to the gearbox. We remove the bolt and move the clutch release cylinder assembly with the bracket to the side.
Using a 19 mm wrench, unscrew the two upper bolts securing the gearbox to the engine cylinder block. After unscrewing the rear upper bolt, move the wiring harness mounting bracket to the side.
We install an adjustable stop under the engine. Straighten the edges of the locking plate. Using a 17 mm wrench, unscrew the three bolts securing the gearbox bracket.
Useful tips
It is almost impossible to determine what kind of oil the manufacturer poured into a car’s gearbox at the factory. But most often this “consumable” turns out to be mineral. And it thickens quite strongly at subzero temperatures. So if you are planning a replacement, it is better to buy semi-synthetic or synthetic lubricant.
Periodically, approximately every 15 thousand kilometers, it is necessary to check the level of consumables. As already mentioned, on the Daewoo Nexia the gearbox oil change is not provided for the entire time the car is used. But there are situations when there is a need for replacement. For example, when repairing a gearbox or when transferring a car to a new “consumables”. If a replacement is planned, then the old fluid should be drained while it is hot. This way it will be more fluid.
Replacing the 5th gear of the gearbox
Hi all. In case anyone will be interested. Now I have my third Ksyukha (8th grade, 2012), before that there were 1998 and 2000. When I took the new one, the manager said that the new 8 cl and the old one only had the engine changed a little and that’s all, but as it turned out, the gear ratios in the gearbox were also changed. And when I was driving her around, I noticed the incredibly short gears. In general, 3000 rpm - 100 km/h in 5th gear did not suit me at all (on the old 8kL, 3000 rpm - 120 km/h). I searched all over the internet and didn't really find anything. In general, I put it in 5th gear from the old 8kL Ksyukha, now at 3000 rpm, about 125 km/h. If anyone is interested, I’ll tell you in detail; you don’t need to remove the gearbox.
Comments
#10 Kostas 12.22.2014 19:13 I quote asil7777:
I had my 1.6 H150 upgraded by EcoSport, and I don’t regret it at all. You drive moderately - consumption is 9l/100, pedal to the floor - 11l
Now this is more interesting. I don’t really know if we have it.
#9 asil7777 12.22.2014 17:56 Quoting Kostas:
That's why I'm going to change the firmware.
I had my 1.6 H150 upgraded by EcoSport, and I don’t regret it at all. You drive moderately - consumption is 9l/100, pedal to the floor - 11l
#8 Kostas 12/22/2014 09:39 I quote asil7777:
Was there any point in overloading an already weak internal combustion engine? at 100 km at 3000 rpm, but it’s playful, especially since 8kL at the bottom gives good results.
As it turned out, the old Ksyukha with her 75 horses is more capable than the new one with 80 horses.
Was there any point in overloading an already weak internal combustion engine? at 100 km at 3000 rpm, but it’s playful, especially since 8kL at the bottom gives good results.
#6 Kostas 12/17/2014 12:13 Unfortunately, I didn’t take any photos, I didn’t think about it then. I have an 8cl A15SMS engine. The old Nexia 8 and 16kl differed in gear ratios in the gearbox, and the new N-150 differed in the main pair. I found a gearbox from 8kl (G15MF engine) with a broken housing, it has the smallest gear ratio in 5th. Important: we change both gears, the synchronizer and the 5th gear fork along with the crackers. The process itself: I raised the left side as high as possible, I didn’t want to drain the oil, and it was more convenient to work. I took off the wheel and there it was, the 5th gear cover. I took off the cover, there were about 10 bolts. Remove the power fork and two hex bolts. I immediately ruined mine (I barely took it off), so I need a good hex wrench and an impact screwdriver. Remove the retaining rings on the gear and synchronous. The synchronizer from the old box, if it has not yet been removed, must be removed carefully, otherwise it will fall apart and you won’t immediately understand what’s what. We remove the gears. The one that came off easily under the synchronizer, but the other one barely came off and had to be pressed out with an assembly tool. Well, assembly, in reverse order. Don't forget about the retaining rings. While you are working, do not poke anything, do not engage the gears, otherwise I stuck the rear one in, I thought I would have to remove the box. After the replacement, at first there was a barely audible click in the gearbox, but after a couple of days everything became the same as before. This is all good, of course, but... As it turned out, the old Ksyukha with its 75 horses is more capable than the new one with 80 horses. Apparently because of this, the transmissions were short. I'm going to chip it with firmware from Paulus. Or another option is to make brain settings like the first Ksyukhas, so that without Euro 3. That seems to be all.
probably the 2nd option, installing R16 wheels)))) and it will be 120 km at 3000 rpm))
I agree, I figured it would be like that somewhere. Only the wheels will cost 20k, but here it cost two rubles.
There is no need to remove the gearbox. Simply remove the fifth gear cover.
#5 asil7777 12/15/2014 5:09 pm I quote simens77:
(embarrassed to ask))) without removing the gearbox
I don’t know what kind of gearbox I have N150 16 valves 2012.
Well then, take it off and look at the sticker, the gearbox volume, if 3.7 knows a hybrid from SONS. And one more thing, “there is no need to remove the gearbox” is like that. lower the tachometer needle by 0.5 level? 4?))
#2 Viktor 12/14/2014 01:18 I quote asil7777:
You know you had a native SONS gearbox, but there is also a gearbox that is installed from a SONS hybrid - a SONS block and a DONS head. At home, to relieve the load during acceleration, the transmitted 4th wheel is reduced
Source
Consequences of untimely replacement
8- and 16-valve Daewoo Nexia requires periodic replacement of transmission oil, since the additive package in the lubricant loses its properties over time. As a result, it becomes inoperable. Because of this, the liquid cannot provide the proper level of protection for rubbing surfaces. The loss of basic properties will lead to foaming of the working substance, which will ultimately cause scuffing of the main gear. As a result, the gears of the transmission differential will begin to hum, that is, the operation of the gearbox will be accompanied by a hum.
Which oil is better to choose?
When changing the oil in a Daewoo Nexia n150 gearbox with 8 or 16 valves, you need to know what kind of lubricant should be poured into the system. The manufacturer does not regulate this replacement. Accordingly, you will not be able to find information about choosing a product in the service book. Practice shows that Daewoo Nexia gearboxes whose owners fill with synthetic or semi-synthetic lubricant last a long time. Initially, when a car is manufactured, mineral oil is used in the gearbox, so when buying a car it is also better to change it to “synthetic” or “semi-synthetic”.
If the climate in your region is moderate, then you can safely use any oil of the SAE 80W GL-4 standard. When operating a car in severe frost conditions, it is better to give preference to the 75W90 GL-4, proven by car enthusiasts. This lubricant is especially suitable for northern regions, where the average air temperature throughout the year is -25 degrees. It is possible to use both synthetic and semi-synthetic oils, but for cold climates “synthetics” are better suited. The use of such fluid in the warm season can lead to noise in the transmission.
Transmission fluid MANNOL Hypoid Getriebeoel 80W-90 API
Replacing the backstage in Daewoo Nexia with your own hands
transmission rod daewoo nexia (Daewoo Nexia) Replacement and repair
The car must be placed on a level surface. Replace the bushings and rubber seals of the drive lever.
Replacement and adjustment of the gear shift mechanism (helicopter) Daewoo Nexia Daewoo Nexia. After removing the gearbox...
Remove the old bushing and install the new one on the joint, pressing the eye onto the bushing until a groove for the retaining ring appears.
Real operating time is from 2.5 hours to 3.5. But we do not tighten the clamp connecting the shaft and gear shift drive. A day, two, and again the programs scattered.
It is clear that this is not an extreme measure, but still the breakdown cannot be called the norm. In this case, replacing the rod in the mechanism responsible for gear shifting is considered using the example of what is used on Nexia, Lanos and Opel Cadet. Everyone knows that the gearboxes on these machines are reliable and, if used properly, will last a long time. Therefore, you just need to change the oil seal, which you can actually do with your own hands.
Most experts say that buying just one oil seal is probably not enough. Often it is necessary to change the rod along with the oil seal, since it is directly related to the gear shift mechanism itself.
Assembling and adjusting the scenes.
Preparatory work
Assembly is carried out in the reverse order of disassembly. The drawstring was secured in the center using a rod with latches. Place the gearshift lever in neutral.
Moving on to the engine compartment, on the right side of the rod that goes into the box, you need to feel the plastic plug. Pull it out and place a drill in the resulting hole. With one hand, take the rod from the gearbox and turn it all the way towards you, facing the car, this will happen in a clockwise direction. At this time, hold the drill with your other hand.
Replacing the Daewoo Nexia rocker
By slightly turning the rod in different directions, you will feel how the drill goes slightly deeper and fixes it. These measures will provide you with easy access from above. From the bottom of the car, loosen the clamp connecting the gearbox lever to the rocker. From above, through the engine compartment, loosen the bolt for the clamp that connects the shift shaft to the drive. Remove the spring clip and pull out the small shaft that connects the shift rod to the rocker.
Turn the axle that connects the gearshift actuator and the bracket counterclockwise, pry it up with a screwdriver and remove it by slightly pulling up. Now that the rocker is disconnected from the lever and from the entire gearbox, it will remain attached with its central part to a closed area located in the engine compartment. There are latches on the top of its fastening rod; press them in different directions and pull the guide rod.
Now you can safely remove the drawstring, pull it out through the top. The bushings on the drive joints should be replaced. Take pliers, remove the retaining ring, disconnect the connection.
If the car is already many years old. Usually it is simply pulled out upwards. But when it sours, you won’t be able to take it out.
If you pull on the record, you will tear it off. It is simply rolled on a pin. If it still hasn’t gone sour, you just need to unclench the plate in the photo and pull it up.
Changing the oil in a car gearbox
DAEWOO NEXIA requires changing (topping up) oil regularly. This is a very important point and it is advisable to ensure that replacement (topping up) is carried out every 15 thousand km.
In general, the car manufacturer created the box in such a way that it does not require an oil change. However, sometimes it is replaced with a more viscous composition or from summer to winter oil, and also if the box has been repaired.
To check whether there is enough oil in the box, you need to lower a screwdriver into the hole (or check the oil level with your finger); it should reach it.
If the level is low, remove the protective cap from the hole and add oil.
It is recommended to drain the oil, in case of replacement, no later than 15 minutes after operating the vehicle. At this time it is most fluid.
Replacement is made using a syringe and socket heads “13” and “17”.
To change the oil, the plug is turned out, the existing composition is drained, and then new oil is poured in.
The hole for this is located on the gearbox housing. A vessel is placed under it to collect the oil.
It is important to remember that the plug in this case plays the additional role of a breather, which means all its holes must be clean. Therefore, before sealing the vessel, it is necessary to clean it with a rag.
Instructions for carrying out work
It is necessary to replace the lubricant on the overpass. The replacement operation is carried out in several stages.
- If there is protection on the engine, remove it.
- The transmission pan bolts will need to be loosened. Tighten the bolts in the front area of the pan and place a prepared container to drain the old “consumables”.
- Once you have drained all the grease, you can remove the pan. If the gasket is not damaged, it will still need to be replaced.
- As a rule, only 1.5 liters of lubricant comes out of the crankcase, approximately 200 g remains in it. If you want to perform a complete drain, you will need to raise the left front wheel as high as possible.
- Unscrew the lubricant level control plug. Clean the inside of the box thoroughly. Also clean the unattached magnet located in it.
- Wait until the gearbox oil stops flowing. Put the tray back. It must be installed with a new gasket. There is no need to tighten the control plug.
- After this, you can pour in new fluid. To do this, you will need to twist the breather at the top of it. Unscrew the cap from the breather. You can remove it with a key number 19.
- Place a funnel in the breather. Start pouring liquid until it comes out of the plug hole. After this, screw on the control plug. As a result, you should be filled with 1.5 liters of lubricant.
- If in order to remove the fluid completely, you had to lift the wheel from the front, then after you close the plug, you will need to add lubricant to the required volume.
- Replace the breather. That's it, the job is finished!
As you can see, there are no difficulties in changing the gearbox oil on a Daewoo Nexia. If you are a beginner, then a video that can be found on the Internet will help you. After changing the lubricant, you will need to make sure that the gear shifts easily at any time of the year. With some effort and spending a small amount of time, any motorist can replace the “consumables” in his car.
