Manual Transaxle System

General Information

Manual Transaxle System

 2010 > D 1.1 TCI-U >

SPECIFICATIONS
Engine type U-1.1
Transaxle type M5CF1
Gear ratio 1st 3.615
2nd 1.950
3rd 1.233
4th 0.886
5th 0.689
Reverse 3.583
Final gear ratio 3.650

TIGHTENING TORQUES
Standard value Nm kgf.m lb-ft
Oil drain plug 60-80 6.0-8.0 43.4-57.8
Oil filler plug 60-80 6.0-8.0 43.4-57.8
Shift control cable bracket 15-22 1.5-2.2 10.8-15.9
Rear roll support bracket bolt 60-80 6.0-8.0 43.4-57.8
Transaxle support bracket bolts 60-80 6.0-8.0 43.4-57.8

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 Grease (CASMOLY L9508) release bearing 0.5~1.0g
bearing 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 > D 1.1 TCI-U >

SPECIAL SERVICE TOOLS

TOOL
Illustration Use
(Number and Name)
09452-21200 Installation of differential oil seal
Oil seal installer

09200-38001 Removal and installation of the transaxle

Engine support fixture
 2010 > D 1.1 TCI-U >

SPECIAL SERVICE TOOLS

TOOL
Illustration Use
(Number and Name)
09452-21200 Installation of differential oil seal
Oil seal installer

09200-38001 Removal and installation of the transaxle

Engine support fixture
 Manual Transaxle System

Manual Transaxle System

Manual Transaxle System

 2010 > D 1.1 TCI-U >

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).

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)

BACKUP LAMP SWITCH

INSPECTION
1. Disconnect the intergrated connector (A).

2. Check the continuity between no.6 and 7 terminals of backup lamp switch when the shift lever is in reverse. If not,
take the next step.

3. Disconnect the backup lamp switch connector(A).

4. Check the continuity between no. 1 and 2 terminals of backup lamp switch.
When the shift lever is in reverse, there should be contunuity.

5. 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)

NEUTRAL SWITCH
INSPECTION
1. Disconnect the integrated connector (A).
2. Check the continuity between no. 2 and 5 terminals when the shift lever is in neutral position. If not, take the next
step.

3. Disconnect the neutral switch connector (A).

4. Check the continuity between no. 1 and 2 terminals of neutral switch, when the shift lever is in neutral position,
there should be continuity.

5. If necessary, repair or replace the neutral switch.

 TORQUE :
35-42 Nm (3.5-4.2 kgf.m, 25.3-30.3 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(09452-21200), tap the drive shaft oil seal into the transaxle.
 Manual Transaxle System

Manual Transaxle System - Manual Transaxle

Manual Transaxle System

2010 > D 1.1 TCI-U >

COMPONENTS
 2010 > D 1.1 TCI-U >

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.

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 wire harness bracket bolts.

6. Disconnect the integrated connector (A) and remove the CKP sensor (B).

7. Remove the shift cables.

Move the bending parts to the arrow direction in the illustration before removing the 'one-touch' clips (A) from
the bracket.
8. Remove the shift cable bracket.

9. Installing the engine supporter(09200-38001), hold the enigne and transaxle assembly safely.

10. Remove the transaxle upper mounting bolts.

11. Remove the transaxle mounting support bracket bolts.

12. Remove the front tires.
13. Remove the under cover.

14. Remove the drive shaft from transaxle. (Refer to Front Driveshaft in DS group)
15. Remove the clutch release cylinder by removing the two bolts (A).

16. Remove the starter motor mounting bolts.

17. Remove the rear roll stopper bracket (A).

18. Remove the transaxle mounting bolts (A,B) from the engine side and the other (C) from the transaxle side.

19. Remove the transaxle lower mounting bolts (A,B).

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.

2. Install the transaxle lower mounting bolts (A,B).

TORQUE :
[A] 43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
[B] 35~50Nm(3.5~5.0kgf.m, 25.3~36.1lb-ft)

3. Install the transaxle mounting bolts (A,B) from the engine side and the other (C) from the transaxle side.

TORQUE :
[A] 43~55Nm(4.3~5.5kgf.m, 31.1~39.7lb-ft)
[B,C] 35~50Nm(3.5~5.0kgf.m, 25.3~36.1lb-ft)

4. Install the rear roll stopper bracket (A).

 TORQUE :
60~80Nm(6.0~8.0kgf.m, 43.4~57.8lb-ft)

5. Install the starter motor mounting bolts.

TORQUE :
39~60Nm(3.9~6.0kgf.m, 28.2~43.4lb-ft)

6. Install the clutch release cylinder by installing the two bolts (A).

TORQUE :
15~22Nm(1.5~2.2kgf.m, 10.8~15.9lb-ft)

7. Install the drive shaft to the transaxle assembly. (Refer to Front Driveshaft in DS group)
8. Install the under cover.
9. Install the front tires.
10. Install the transaxle mounting support bracket bolts.

TORQUE :
60~80Nm(6.0~8.0kgf.m, 43.4~57.8lb-ft)

11. Install the transaxle upper mounting bolts.

TORQUE :
60~80Nm(6.0~8.0kgf.m, 43.4~57.8lb-ft)

12. Remove the engine supporter(09200-38001).

13. Install the shift cable bracket.

TORQUE :
15~22Nm(1.5~2.2kgf.m, 10.8~15.9lb-ft)

14. Install the shift cable by using new 'one-touch' clips (A).

15. Connect the integrated connector (A) and install the CKP sensor (B).
16. Install the wire harness bracket bolts.

17. Install the lower cover of the air cleaner assembly.

18. Install the upper cover (B) of the air cleaner assembly by tightening the clamp (A).

19. Install the battery tray (A).

20. Install the battery and the battery (A) terminal.

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.
 Manual Transaxle System

Manual Transaxle Control System - Manual

Transaxle Shift Control

Manual Transaxle System

2010 > D 1.1 TCI-U >

COMPONENTS
 2010 > D 1.1 TCI-U >

REMOVAL
1. Remove the floor console switch(A) and connector.

2. Remove the center console(A).(Refer to BD group.)

3. Remove the select cable snap pin(A).

4. Remove the shift cable clip(A).

5. Remove the shift cable(A) and select cable(B).
6. Remove the shift lever assembly(C).

7. Remove the retainer(A) and nuts(B).

8. Remove the snap pins(2EA).(Transaxle side).

9. Remove the shift cable and select cable.

INSTALLATION
1. Install the shift cable and select cable after locating the shift lever and select lever at the neutral position.

When operating lever of body side, check secure operation of lever of transaxle side after assembly.

2. Install the snap pins(2EA) of transaxle side.

3. Install the shift lever assembly.

TORQUE:
9-14Nm(90-140kgf.cm, 6-9.5lb.ft)

4. Disconnect the clip (A) and the locking piece (B) from the select cable as shown in the illustration.

Be sure to confirm that the locking piece is movable before adjusting the select cable length in the direction
(C) shown in the illustration.

5. Insert the select lever pin to the select cable and install the snap pin (A) placing the select lever in neutral position
and adjusting free play of the select cable.
6. Install the locking piece (A) in the direction as shown in the illustration.

7. Install the clip (A) in the direction as shown in the illustration.z

Adjust the cable length with select cable adjuster in "N" position before installing the center console.

8. Install the center console.(Refer to BD group.)

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.