M5GF2, M5HF2 CM Manual Transaxle

2 Line up Introduction

3 M5/6GF2 Transaxle

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

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

6 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

7 Input shaft : 5 th gear & front bearing removal & assembly - Remove the front bearing and 5 th gear together. - 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

8 Input shaft : 3 rd – 4 th gear & rear bearing removal & assembly - Remove the rear bearing and 3 rd –4 th gear together after heating the gear the 3 rd – 4 th gear) - Assembly, replacement and the part supply: Same as in the case of 5 th gear. M5/6GF2

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

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

11 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

12 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 Spacer M5/6GF2

13 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

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

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

16 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

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

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

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

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

21 5 th -6 th fork [Output shaft #2] Reverse fork [Output shaft #1] Plastic guides on the shift fork M5/6GF2

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

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

24 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 M5/6GF2

25 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 Spacer M5/6GF2

26 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 ) M5/6GF2

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

28 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 M5/6GF2

29 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. M5/6GF2

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

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

32 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 M5/6GF2

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

34 The direction for synchronizer (M5GF2 Model) 1st 2nd 1&2 sleeve 3rd4th 3&4 sleeve 5th6th 5&6 sleeve R R sleeve M5/6GF2

35 [1&2 sleeve, 3&4 sleeve] - Both sides have different chamfer angles to recognize the own direction while assembling the sleeve. - It is not easy to identify the difference of angle visually, but in reality the angles for both sides are not same each other (See the picture on the next page) - The reason of the different angle is for the performance of transaxle and the specific angle value is a confidential data. - Therefore, the miss-assembling may affect the durability and performance. [5&6 sleeve] - There is no direction in this one. [Reverse sleeve] - Only one side has a chamfer angle (The other side has nothing) - It is different caused by its structure. The direction for synchronizer (M5GF2 Model) M5/6GF2

36 Chamfer angle The direction for synchronizer (M5GF2 Model) M5/6GF2

37 M5HF2 HTX (Length: 416.7) M5HF2 (Length: 392.5) INPUT(3,4,5,R) OUTPUT(1,2) OUTPUT #1 INPUT OUTPUT #2 (5,R) OUTPUT #1 (1,2,3,4) Comparison OUTPUT #2

38 M5HF2

39 M5HF2

40 M5HF2

41 M5HF2

42 M5HF2

43 M5HF2

44 Concentric Slave Cylinder M5/6GF2M5HF2

45 M5/6GF2 Concentric Slave Cylinder Air bleeder body To Quick connector

46 Concentric Slave Cylinder For M5HF2For M5/6GF2

47 Self Adjusting Clutch SAC (Self Adjusting clutch) Coil spring Adjusting ring