TUCSON(LM) > 2012 > G 2.
0 DOHC > Manual Transaxle System
Manual Transaxle System > General Information > Specifications (M5GF1)
Specifications
Manual transaxle type M5GF1
Engine type Gasoline 2.0
1st 3.636
2nd 2.080
3rd 1.333
Gear ratio
4th 1.061
5th 0.821
Reverse 3.455
Final gear ratio 4.533
T/M oil capacity ※ 2.1L (0.14 U.S.gal., 0.55 U.S.qt., 0.46 lmp.qt.)
※ The quantity in the chart above is for the reference. The actual filling quantity of the automatic
transaxle fluid must be set according to 'INSPECTION' or 'REPLACEMENT' procedure of the manual
transaxle fluid.
Recommended transaxle oil SAE75W/85 or API GL-4
Check&Replenishment Every 30 months or every 60,000km
Normal use No service required
Private use
Replacement Severe use(※)
Every 120,000 Km
Business use
※ Severe use(marked '※') is defined as:
1. Driving on rough road(bumpy road, gravel road, snowy road, unpaved road etc.).
2. Driving on mountain road, ascent/descent.
3. Repetition of short distance driving.
4. More than 50% operation in heavy city traffic during hot weather above 32°C(89.6°F).
5. Police car, Taxi, Commercial type operation or trailer towing, etc.
Lubricants
Item Lubricant Quantity
Transaxle input shaft splin CASMOLY L9508 0.2 gr.
Transaxle case gasket LOCTITE 587 As required
Tightening Torques
Item N.m kgf.m lb-ft
Magnetic plug 29.4~34.3 3.0~3.5 21.7~25.3
Shift control cable bracket 19.6~26.5 2.0~2.7 4.5~19.5
Oil filler plug 34.3~44.1 3.5~4.5 25.3~32.6
Idler shaft bolt 34.3~41.2 3.5~4.2 25.3~30.4
Back up lamp switch 29.4~34.3 3.0~3.5 21.7~25.3
Vehicle speed sensor 2.9~3.9 0.3~0.5 2.2~3.6
Transaxle mounting bracket assembly 59.2~78.9 6.0~8.0 43.6~58.2
Transaxle upper mounting bolt 42.2~53.9 4.3~5.5 31.1~39.8
Transaxle lower mounting bolt 42.2 ~ 48.1 4.3 ~ 4.9 31.1 ~ 35.4
42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Manual Transaxle System > General Information > Special Service Tools
(M5GF1)
Special Service Tools
Tool
Illustration Use
(Number and name)
09200-38001 Removal and installation of the
Engine support fixture transaxle.
(Beam) Except lower supporter, use beam
only with new engine support fixture
supporter(SST No.:09200-2S000)
09200 - 2S000 Removal and installation of the
Engine support fixture transaxle.
(Supporter) Use this supporter with the upper
beam of the engine support
fixture(SST No.:09200-38001)
Manual Transaxle System > Manual Transaxle System > Repair procedures
(M5GF1)
Service Adjustment Procedure
Transmission Oil Inspection And Replacement
1. After parking the vehicle on a plain, stop the engine.
2. After removing the oil filler plug and washer, inspect the manual transaxle fluid condition and
quantity.
3. If the manual transaxle fluid is contaminated, drain it out by removing the oil drain plug.
4 Tighten the new oil drain plug and feed manual transaxle fluid to a proper level.
.
Tightening torque :
29.4~34.4 N.m(3.0~3.5kgf.m, 21.7~25.3lb-ft)
Oil type: SAE75W/85 or API GL-4
Oil quantity:
2.1L (0.14 U.S.gal., 0.55 U.S.qt., 0.46 lmp.qt.)
5 Retighten the oil filler plug with a new washer.
.
Tightening torque :
29.4~34.4 N.m(3.0~3.5kgf.m, 21.7~25.3lb-ft)
Back Up Lamp Switch Inspection
1. Disconnect the back up lamp switch connector(A).
2. Inspect the continuity of the switch. When the shift lever is located in reverse range, it should be
applied an electric current.
3 Replace the back up lamp switch, if necessary.
.
Tightening torque :
29.4~34.4 N.m(3.0~3.5kgf.m, 21.7~25.3lb-ft)
Manual Transaxle System > Manual Transaxle System > Manual Transaxle >
Components and Components Location (M5GF1)
Components
1. Snap ring 15. Differential taper roller bearing
2. 5th speed gear 16. Differential
3. 4th speed gear sleeve 17. Differential drive gear
4. Reverse idler bolt 18. Drain plug
5. 4th speed gear 19. 2nd speed gear sleeve
6. 3&4th synchronizer hub & sleeve 20. 3rd speed input gear
7. 3rd speed gear 21. 4th speed input gear
8. 1&2nd synchronizer hub & sleeve 22. 5th speed gear sleeve
9. 1st speed gear 23. Rear output shaft taper roller bearing
10. Cutch housing 24. Reverse driven gear sleeve
11. Front input shaft ball bearing 25. 5th & REV synchronizer hub & sleeve
12. Input shaft 26. Rear input shaft ball bearing
13. Front output shaft taper roller bearing 27. Reverse idler gear
14. Output shaft
Manual Transaxle System > Manual Transaxle System > Manual Transaxle >
Repair procedures (M5GF1)
Removal
1. Remove the battery and battery tray (D). (Refer to "Charging System" in EE group)
2. Remove the engine cover (B). (Refer to "Intake and Exhaust System" in EM group)
3. Remove the air cleaner assembly (C). (Refer to "Intake and Exhaust System" in EM group)
4. Remove the air duct(A). (Refer to "Intake and Exhaust System" in EM group)
5. Remove the ground circuit line(A) from the transaxle.
6. Remove the back up lamp switch(A) and Vehicle speed sensor(B).
7. Remove the shift cable assembly(A).
8 Remove the clutch release cylinder(A).
.
Tightening torque :
63.7~73.5N.m (6.5~7.5kgf.m, 47.0~54.2lb-ft)
9. Remove the cowl top cover or wiper motor. (Refer to "Windshield Wiper/Washer" in BE group.)
10. Remove the cowl complete assembly panel(A).
11. Using the engine support fixture (Support SST No.: 09200-2S000, Beam SST No.: 09200-38001),
hold the engine and transaxle assembly safely.
12 Supporting the transaxle with a jack, remove the transaxle support bracket(A) and the upper
. mounting bolts(B).
Tightening torque :
(A) 59.2~78.9N.m (6.0~8.0kgf.m, 43.6~58.2lb-ft)
(B) 42.2~53.9N.m (4.3~5.5kgf.m, 31.1~39.8lb-ft)
13. Remove the under shield cover(A).
14. Drain the manual transaxle fluid after removing the transaxle drain plug(A). It can be easier when
the oil filler plug(B) is removed.
15. Remove the following items;
A. Drive shaft assembly. (Refer to "Drive shaft assembly " in DS group.)
B. Sub frame assembly. (Refer to "Front suspension system" in SS group)
C. In the case of 4WD vehicle, remove the transfer assembly. (Refer to "Transfer assembly" in
WD group)
In the case of 2WD vehicle, not remove the transfer assembly.
16. Lowering the jack slowly, remove the transaxle.
17 Remove the transaxle lower mounting bolts(A).
.
Tightening torque :
(A) 42.2~48.1N.m (4.3~4.9kgf.m, 31.1~35.4lb-ft)
(B) 42.2~53.9N.m (4.3~5.5kgf.m, 31.1~39.8lb-ft)
Installation
1. Installation is reverse of removal.
A. Refill the transaxle fluid. (Refer to "manual transaxle system" in this group.)
B. Refill the power steering fluid and bleed the air.(Refer to "general information"in ST group)
C. Refill the brake fluid and bleed the clutch hydaulic system. (Refer to "clutch system"in CH
group)
Manual Transaxle System > Manual Transaxle Control System > Manual
Transaxle Shift Control > Components and Components Location (M5GF1)
Components
1. Knob 4. Shift cable assembly
2. Shift lever assembly 5. Shift lever assembly (MT side)
3. Select cable assembly 6. Manual transaxle assembly
Manual Transaxle System > Manual Transaxle Control System > Manual
Transaxle Shift Control > Repair procedures (M5GF1)
Removal
1. Remove the center console. (Refer to "Console" in BD group)
2. Remove the snap pin (B) and the clip (A) from the select cable assembly.
3. Remove the clip (A) from the shift cable assembly.
4 Remove the shift lever assembly(A).
.
Tightening torque :
8.8~13.7N.m(0.9~1.4kgf.m, 6.5~10.1lb-ft)
5. Remove the retainer(A) and nuts(B).
6. Remove the select and shift cable assembly from the transaxle. (Refer to Transaxle removal)
Inspection
1. Check the select cable for proper operation and for damage.
2. Check the shift cable for proper operation and for damage.
3. Check the boots for damage.
4. Check the boots for wear abrasion sticking, restricted movement or damage.
5. Check for the weak or damaged spring.
Installation
1. Installation is the reverse of removal.
2. Move the slide clip (B) of guide member (A) in the direction as shown in the illustration.
Adjust the slide clip fit into the select lever moving the slide clip in the direction (C).
3. Install the guide member (A) of the select cable (B).
4. Adjust the slide clip (B) to fit it into the select lever pin (A) and install the snap pin (C).
Insert the slide clip in the direction as shown in the illustration.
