NF – SONATA MANUAL TRANSAXLE M5/6GF2 September, 04 Chonan Technical Service Training Center

2 M5/6GF2 Transaxle Transaxle

3 Input Shaft Reverse Shaft Output#2 Shaft Output#1 Shaft Differential Shaft Three shafts layout M5/6GF2 Transaxle

4 IPOP2OP1 2 nd gear 1 st gear Reverse gear 5 th / R (Share) 5 th gear 3 rd gear 4 th gear Gear train 6 th gear 4 th / 2 nd (Share) M5/6GF2 Transaxle

5 Front Input shaft structure (M5GF2) Spacer Rear bearing 3 rd -4 th gear 5 th gear Front bearing Snap ring Spec.: mm (L) M5/6GF2 Transaxle

6 Input shaft : 5 th gear & front bearing removal & assembly - Remove the front bearing and 5 th gear together. (It is possible to do it on the hydraulic press without heating the 5 th gear) - But it is the best way to use the heater for preventing the part from any damage. - Especially when assemble the 5 th gear, it is highly recommended to use the heater. (Minus clearance: the shaft is thicker than 5 th gear about 0.2mm) - It will be the most simple way to replace the input shaft assembly with new one. (Workshop manual recommends to do that) - However, all parts such as gear, spacer, input shaft will be supplied as a part. M5/6GF2 Transaxle

7 Input shaft : 3 rd – 4 th gear & rear bearing removal & assembly - Remove the rear bearing and 3 rd –4 th gear together. (It is possible to do it on the hydraulic press without heating the 3 rd – 4 th gear) - Assembly, replacement and the part supply: Same as in the case of 5 th gear. M5/6GF2 Transaxle

8 Output shaft #1 structure (M5GF2) Reverse gear Key spring Rear 1 st gear 2 nd gear M5/6GF2 Transaxle Front

9 Output shaft #1 disassembly - Front bearing removal SST ( A000) or equivalent oneReverse gear - Remove the front bearing and installing the SST. M5/6GF2 Transaxle

10 Output shaft #1 disassembly - Rear bearing & 2 nd gear removal 2 nd gear - Remove the rear bearing and spacer together with 2 nd gear using the hydraulic press after removing the snap ring. M5/6GF2 Transaxle

11 Output shaft #1 assembly - Not possible to assemble the spacer using hammer. (In case of lower limit dimension) - Spacer on the 2 nd gear must be fitted by hydraulic press M5/6GF2 Transaxle Spacer

12 Output shaft #1 disassembly - 1 st gear & synchronizer hub(1 st -2 nd ) removal 1 st gear - Remove the synchronizer hub together with 1 st gear using the hydraulic press. Synchronizer hub M5/6GF2 Transaxle

13 Output shaft #1 assembly : 1 st- 2 nd synchronizer hub direction Rear side (Four oil guides)Front side (Three oil guides) M5/6GF2 Transaxle

14 Triple synchronizer cone Three faces (1 st,2 nd,3 rd ) M5/6GF2 Transaxle

15 Output shaft #1 disassembly - Reverse gear & synchronizer hub removal - Remove the synchronizer hub together with Reverse gear using the hydraulic press. Reverse gear Synchronizer hub M5/6GF2 Transaxle

16 Output shaft #1 assembly : Reverse synchronizer hub direction Rear side (Three oil guides)Front side (Four oil guides) M5/6GF2 Transaxle

17 Double synchronizer cone Two faces (4 th, Reverse) M5/6GF2 Transaxle

18 Output shaft #1 assembly : Key spring for Reverse synchronizer Reverse synchronizer hub Key spring (Reverse hub with rear direction only) M5/6GF2 Transaxle

19 Output shaft #1 assembly : Gear Clearance M5/6GF2 Transaxle Reverse gear Gauge mm 1 st gear Gauge mm 2 nd gear Gauge mm

20 5 th -6 th fork [Output shaft #2] Reverse fork [Output shaft #1] Plastic guides on the shift fork M5/6GF2 Transaxle

21 Synchronizer key assembly (Ball & spring) Ball Spring (inside) Housing M5/6GF2 Transaxle

22 Output shaft #2 structure M5/6GF2 Transaxle 5 th gear Rear Front Spacer 3 rd gear 4 th gear

23 M5/6GF2 Transaxle Output shaft #2 disassembly - 4 th gear & Rear bearing removal - Remove the rear bearing and spacer together with 4 th gear using the hydraulic press after removing the snap ring. 4 th gear

24 Output shaft #2 assembly - Not possible to assemble the spacer using hammer. (In case of lower limit dimension) - Spacer on the 4 th gear must be fitted by hydraulic press M5/6GF2 Transaxle Spacer

25 M5/6GF2 Transaxle Output shaft #2 disassembly - 3 rd gear & synchronizer hub(3 rd –4 th ) removal - Remove the synchronizer hub for 3 rd /4 th together with 3 rd gear using the hydraulic press. 3 rd gear Synchronizer hub (3 rd /4 th )

26 Output shaft #2 assembly : 3 rd -4 th synchronizer hub direction Rear side (Four oil guides)Front side (Three oil guides) M5/6GF2 Transaxle

27 M5/6GF2 Transaxle Output shaft #2 disassembly - Spacer removal Spacer - Remove the spacer using the hydraulic press and it must be used again while passing the spline for synchronizer hub(3 rd -4 th ) after carefully aligning the splines for both shaft and spacer. Spline

28 M5/6GF2 Transaxle Output shaft #2 disassembly - 5 th gear & synchronizer hub(5 th –6 th ) removal 5 th gear Synchronizer hub (5 th – 6 th ) - Remove the synchronizer hub for 5 th /6 th together with 5 th gear using the hydraulic press.

29 Output shaft #2 assembly : 5 th -6 th synchronizer hub direction Rear side (Four oil guides)Front side (Three oil guides) M5/6GF2 Transaxle

30 Single synchronizer cone One face (5 th gear) M5/6GF2 Transaxle

31 M5/6GF2 Transaxle Output shaft #2 disassembly -Front bearing removal No gap to install the removing plate (Bearing cannot be reused) Bearing outer race removal Bearing inner race removal

32 Output shaft #2 assembly : Gear Clearance M5/6GF2 Transaxle 5 th gear mm Gauge 3 rd gear mm Gauge 4 th gear mm

33 M5/6GF2 Clutch system CSC

34 M5/6GF2 Clutch system CSC

35 M5/6GF2