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Manual Transaxle System
General Information
Manual Transaxle System
2010 > G 1.0 SOHC >
SPECIFICATIONS
Engine type Gasoline 1.1
Transaxle type M5EF2
Gear ratio 1st 3.545
2nd 1.894
3rd 1.192
4th 0.853
5th 0.719
Reverse 3.636
Final gear ratio 4.437
TIGHTENING TORQUES
Standard value Nm kgf.m lb-ft
Oil drain plug 60-80 6.0-8.0 43.4-57.8
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Oil filler plug 60-80 6.0-8.0 43.4-57.8
Shift control cable bracket 20-27 2.0-2.7 14.5-19.5
Rear roll support bracket bolt 43-55 4.3-5.5 31.1-39.7
Transaxle support bracket bolts 43-55 4.3-5.5 31.1-39.7
Always follow torque tightening levels. Failure to follow such levels can result in parts breaking if over-tightened or
loosening if under-tightened. In either case, serious personal injury or death could result to vehicle occupants.
LUBRICANTS
Items Recommnend lubricant Quantity
SAE 75W/85
API GL-4
TGO-7(MS517-14)
Transaxle gear oil 1.9L(2.0US qt, 1.67lmp qt)
ZIC G-F TOP 75W/85(SK)
HD GEAR OIL XLS
75W/85(H.K.SHELL)
Air breather MS721-38 As requried
Transaxle housing MS721-40 or MS721-38 As requried
Surface of release fork and bearing Grease (CASMOLY L9508) release bearing 0.5~1.0g
release bearing and fork 0.3~0.5g
release fork and fulcram 0.5~10.g
release fork and clutch felease cylinder 0.4~0.8g
2010 > G 1.0 SOHC >
SPECIAL SERVICE TOOLS
TOOL
Illustration Use
(Number and Name)
09431-21000 Installation of differential oil seal.
Oil seal installer
09200-38001 Removal and installation of the transaxle.
Engine support fixture
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2010 > G 1.0 SOHC >
TROUBLESHOOTING
Symptom Probable cause Remedy
Vibration, noise Loose or damaged transaxle and engine mounts Tighten or replace mounts
Inadequate shaft end play Correct end play
Worn or damaged gears Replace gears
Inadequate grade of oil Replace with specified oil
Low oil level Replenish
Inadequate engine idle speed Adjust idle speed
Oil leakage Broken or damaged, oil seal or O-ring Replace control cable oil seal or O-ring
Hard shift Faulty control cable Replace control cable
Poor contact or wear of synchronizer ring and gear
Correct or replace
cone
Weakened synchronizer spring Replace synchronizer spring
Inadequate grade of oil Replace with specified oil
Jumps out of gear Worn gear shift fork or broken poppet spring Replace shift fork or poppet spring
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Synchronizer hub-to-sleeve spline clearance too
Replace synchronizer hub and sleeve
large
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Manual Transaxle System
Manual Transaxle System
Manual Transaxle System
2010 > G 1.0 SOHC >
SERVICE ADJUSTMENT PROCEDURE
TRANSAXLE GEAR OIL LEVEL
INSPECTION
Inspect each component for evidence of leakage.
Check the gear oil level by removing the filler plug.
If the oil is contaminated, it is necessary to replace it with new oil.
1. Remove oil filler plug (A).
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2. Check level with finger.
Oil level must be up to fill the hole, add oil until it runs over.
3. Install the filler plug with new washer.
TORQUE :
60-80 Nm (6.0-8.0 kgf.m, 43.4-57.8 lb-ft)
REPLACEMENT
1. With the vehicle parked on a level surface, remove the drain plug.
2. Drain the transaxle oil after loosening the drain plug (A).
3. Install the drain plug with new washer.
TORQUE :
60-80 Nm (6.0-8.0 kgf.m, 43.4-57.8 lb-ft)
4. Add new oil through the fille plug hole and, fill it ot just below the plug opening.
Standard oil : SAE 75W/85, API GL-4
Oil capacity: 1.9 liter (2.0 US qt, 1.67 lmp qt)
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BACKUP LAMP SWITCH
INSPECTION
1. Disconnect the backup lamp switch connector(A).
2. Check the continuity between no. 1 and 2 terminals of backup lamp switch.
When the shift lever is in reverse, there should be contunuity.
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3. If necessary, repair or replace the backup lamp switch.
TORQUE :
30-35 Nm (3.0-3.5 kgf.m, 21.7-25.3 lb-ft)
DRIVE SHAFT OIL SEAL
REPLACEMENT
1. Remove the drive shaft from the transaxle. (refer to Front Driveshaft in DS group)
2. Using a flat-tip screwdriver, remove the oil seal.
3. Using the special tool(09431-21000), tap the drive shaft oil seal into the transaxle.
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Manual Transaxle System
Manual Transaxle System - Manual Transaxle
Manual Transaxle System
2010 > G 1.0 SOHC >
COMPONENTS
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2010 > G 1.0 SOHC >
REMOVAL
• Use fender covers to avoid damaging painted surfaces.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
• Mark all wiring and hoses to avoid misconnection.
1. Remove the battery after removing the battery (A) terminal.
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2. Remove the battery tray (A).
3. Remove the upper cover (B) of the air cleaner by loosening the clamp (A).
4. Remove the lower cover of the air cleaner assembly.
5. Remove the clutch cable bracket (A).
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6. Remove the wire harness bracket bolts.
7. Disconnect the back up lamp switch connector (A) and the vehicle speed sensor connector (B).
8. Remove the transaxle control cables.
Move the bending parts to the arrow direction in the illustration before removing the 'one-touch' clips (A) from
the bracket.
9. Remove the transaxle control cable bracket.
10. Remove the ground cable.
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11. Installing the engine supporter(09200-38001), hold the enigne and transaxle assembly safely.
12. Remove the transaxle upper mounting bolts (A) and the starter mounting bolts (B).
13. Remove the transaxle mounting support bracket bolts.
14. Remove the front tires.
15. Remove the under cover.
16. Remove the drive shaft from transaxle. (Refer to Front Driveshaft in DS group)
17. Remove the rear roll stopper bracket (A).
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18. Remove the transaxle mounting bolts (A) from the engine side and the other (B) from the transaxle side.
19. Remove the dust cover (A).
20. Remove the transaxle assembly from the engine assembly.
When removing the transaxle assembly, be careful not to damage any surrounding parts or body components
INSTALLATION
1. Temporarily install the transaxle assembly to the engine assembly.
Be careful not to damage any surrounding parts or body components.
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2. Install the dust cover (A).
TORQUE :
8~10Nm(0.8~1.0kgf.m, 5.8~7.2lb-ft)
3. Install the transaxle mounting bolts (A) from the engine side and the other (B) from the transaxle side.
TORQUE :
43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
4. Install the rear roll stopper bracket (A).
TORQUE :
43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
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5. Install the drive shaft to the transaxle assembly. (Refer to Front Driveshaft in DS group)
6. Install the under cover.
7. Install the front tires.
8. Install the transaxle mounting support bracket bolts.
TORQUE :
43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
9. Install the transaxle upper mounting bolts (A) and the starter mounting bolts (B).
TORQUE :
[A] : 43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
[B] : 27~34Nm(2.7~3.4kgf.m, 19.5~24.6lb-ft)
10. Remove the engine supporter(09200-38001).
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11. Install the transaxle control cable bracket.
TORQUE :
20~27Nm(2.0~2.7kgf.m, 14.5~19.5lb-ft)
12. Install the transaxle control cable by using new 'one-touch' clips (A).
13. Install the wire harness bracket bolts.
14. Connect the backup lamp switch connector (A) and the vehicle speed sensor connector (B).
15. Install the clutch cable bracket (A).
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16. Install the lower cover of the air cleaner assembly.
17. Install the upper cover (B) of the air cleaner assembly by tightening the clamp (A).
18. Install the battery tray (A).
19. Install the battery and the battery (A) terminal.
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Perform the following :
• Adjust the shift cable.
• Refill the transaxle with fluid.
• Clean the battery posts and cable terminals with sandpaper, assemble them, then apply grease to prevent
corrosion.
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Manual Transaxle System
Manual Transaxle Control System - Manual
Transaxle Shift Control
Manual Transaxle System
2010 > G 1.0 SOHC >
COMPONENTS
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