MT PDF
MT PDF
MT PDF
(M5GF2)
GENERAL TRANSFER CASE ASSEMBLY
TRANSFER CASE
MANUAL TRANSAXLE SYSTEM TRANSFER DRIVE GEAR
MANUAL TRANSAXLE HYPOID GEAR
MANUAL TRANSAXLE SHIFT CONTROL SYS- PINION SHAFT AND CASE
TEM COUPLING ASSEMBLY
MT -2 MANUAL TRANSAXLE (M5GF2)
GENERAL
SPECIFICATION ED0183A6
※ The quantity in the chart above is for the reference. The be set according to ’INSPECTION’ or ’REPLACEMENT’
actual filling quantity of the automatic transaxle fluid must procedure of the automatic transaxle fluid.
※ Severe use(marked ’※’) is defined as: 4. More than 50% operation in heavy city traffic during
hot weather above 32 C(89.6 F).
1. Driving on rough road(bumpy road, gravel road,
snowy road, unpaved road etc.). 5. Police car, Taxi, Commercial type operation or trailer
towing, etc.
2. Driving on mountain road, ascent/descent.
TIGHTENING TORQUE
SERVICE STANDARD
LUBRICANTS E71A8BF7
Item
Illustration Use
(Number & Name)
09452-21200 Oil seal installation
Oil seal installer
AMJF002A
AMJF002B
UMQG010A
UMQG010B
D3233200
GENERAL MT -5
Item
Illustration Use
(Number & Name)
09478-26100 Removal of 4WD coupling backing plate
Backing plate remover
EKJD506Z
EKJA006A
MT -6 MANUAL TRANSAXLE (M5GF2)
MANUAL TRANSAXLE 2. Inspect the continuity of the switch. When the shift
lever is located in reverse range, it should be applied
SYSTEM an electric current.
TORQUE:
29.4~34.4 Nm(3.0~3.5kgf.m, 21.7~25.3lb-ft)
Oil type: SAE75W/85
Oil quantity:
1.9 liter(2.0077 US qt, 1.6718 lmp qt)
TORQUE:
29.4~34.4 Nm(3.0~3.5kgf.m, 21.7~25.3lb-ft)
KMRE009E
MANUAL TRANSAXLE SYSTEM MT -7
MANUAL TRANSAXLE
COMPONENTS E3ECD674
1
2
5
11 6
7
8
8
9
12 2
17
10
14
13
2
16
15
REMOVAL E1C16812 4. Remove the air cleaner hose(B) and loosen the clamp
bolt(A).
CAUTION
A
• Use a cover not to damage the vehicle sur-
face.
• Disconnect connectors carefully not to be
damaged. B
NOTE
• Mark wires or hoses for identification not to be
confused.
B
A
SCMMT6001D
SCMAT6004D
SCMMT6001L
SCMAT6005D
MANUAL TRANSAXLE SYSTEM MT -9
7. Remove the battery tray (B) by removing the four 10. Remove the control cable assemblies(A) by removing
mounting bolts (A). the snap pins(B) and clips(C).
A A
SCMMT6005D
SCMMT6003L
C
9. Disconnect the vehicle speed sensor connector (A)
and the back up lamp switch(B). B A
B
KMRE009F
AMLF012A
MT -10 MANUAL TRANSAXLE (M5GF2)
13. Support the engine and transaxle by using the special 18. Remove the under cover(A).
tool (09200-38001).
09200-38001
SCMMT6026L
SCMMT6004L
19. Drain power steering oil through the return tube. (see
14. Remove the transaxle insulator bracket (B) by remov- ST group)
ing the bolts (A).
20. Disconnect the power steering pressure hose (A) from
the power steering oil pump.
16. Lift up the vehicle. 27. In case of 4WD, remove the transfer case assem-
bly.(See ’Transfer case’ removal).
17. Remove the steering column joint bolt. (see ST
group). 28. Remove the mounting bolts of lower part of the
transaxle, and the left side cover and remove the
transaxle assembly by supporting it with a jack.
MANUAL TRANSAXLE SYSTEM MT -11
TORQUE:
65~85 Nm(6.5~8.5 kgf.m, 47.0~61.5 lb-ft)
group)
12. Refill transaxle oil through the inlet hole(A).
6. Install the transaxle insulator (B) and mounting
bracket (C) by tightening the bolts (A). TORQUE:
30~35 Nm(3.0~3.5 kgf.m, 21.8~25.4 lb-ft)
TORQUE:
60~80 Nm (6~8 kgf.m, 43.6~58.2 lb-ft)
13. Install the under cover(A).
KMRE009W SCMMT6026L
7. Install the sub frame. (see SS group) 14. Install the front wheels and tires. (see SS group)
TORQUE:
60~80 Nm(6.0~8.0 kgf.m, 65.1~79.5 lb-ft)
MT -12 MANUAL TRANSAXLE (M5GF2)
15. Tighten the transaxle mounting bolts and remove the 18. Install the vehicle speed sensor connector (A).
SST (09200-38001) holding the engine and transaxle
B
assembly.
TORQUE:
65~85Nm(6.5~8.5kgf.m, 47.0~61.5 lb-ft)
09200-38001
AMLF012A
19. Install the ground wire (A) from the transaxle case.
SCMMT6005L
SCMMT6003L
20. Install the battery tray (B) by removing the four mount-
ing bolts (A).
KMRE009D
SCMMT6005D
MANUAL TRANSAXLE SYSTEM MT -13
21. Install the air cleaner assembly (B) by tightening the 24. Connect the AFS connector (A).
two mounting bolts(A).
A
A
SCMMT6009L
A
A
SCMMT6001D
A 27. Install the engine cover and the inter cooler assem-
bly.(See ’EM’ group)
SCMMT6020L
MT -14 MANUAL TRANSAXLE (M5GF2)
COMPONENTS(1) E154A40E
COMPONENTS(2)
[LHD]
[RHD]
SCMMT6029R
3. Remove the snap pin(A) from the select cable and the
SCMMT6028D clips(B).
[RHD] B
SCMMT6030D
A SCMMT6031D
SCMMT6029D
MT -18 MANUAL TRANSAXLE (M5GF2)
A
SCMMT6032D
AMJF500A
AMJF500A
INSPECTION E9EE6C5E
SCMMT6061D
1. Check the select cable for proper operation and for
damage.
4. Install the clip(A) connecting the shift cable and the 6. Install the guide member(A) of the select cable(B).
shift lever.
B
A
A
AMLF006A
SCMMT6031D
NOTE NOTE
Adjust the slide clip fit into the select lever moving the Insert the slide clip in the direction as shown in the
slide clip in the direction. illustration.
A
B
C A
B
AMLF005A AMLF007A
MT -20 MANUAL TRANSAXLE (M5GF2)
8. Install the center console(A). 9. Install the upper cover(A) to the center conole.
[LHD] [LHD]
SCMMT6029D SCMMT6028D
[RHD] [RHD]
SCMMT6029R SCMMT6028R
TRANSFER CASE ASSEMBLY MT -21
TRANSFER CASE -
-
Input torque (Throttle position sensor)
Cornering situation (Steering angle sensor)
ASSEMBLY - Vehicle speed and different wheel speed front &
rear (Wheel speed sensor)
POWER FLOW MECHANISM E2A1A036
- Braking situation (Brake signal and ABS signal)
• Normal driving situation: 2WD base driving 2. Distributed the required driving force after 4WD ECU
• 4WD driving in driving situations (rapid activation, cor- operates.
nering etc.)
3. EMC (Electric Magnetic Clutch) operates the primary
1. Input the information from each sensor in vehicle clutch.
Clutch housing
Clutch plates
Coil
Compress primary
Armature
Magnetic field
Input torque
from propellar shaft
EKQE003C
MT -22 MANUAL TRANSAXLE (M5GF2)
Apply cam
Base cam
Apply force
Base cam
Primary torque
in base cam
Ball
EKQE004C
TRANSFER CASE ASSEMBLY MT -23
Clutch housing
Clutch plates
Compress
secondary
Back plate
Apply cam
EKQE005C
MT -24 MANUAL TRANSAXLE (M5GF2)
Transfer
* 4WD ECM
Coupling
EKQE001C
TRANSFER CASE ASSEMBLY MT -25
Determine Clutch
Slip Error based
on expected and Convert new
measured wheel target torque
torque request torque request to
speeds =last torque Yes = last torque duty cycle control
request ? request based on clutch
model
No
Process Clutch
Slip Error for target torque
Allowance based Yes >last torque No End
on vehicle speed request ?
ELQE214A
MT -26 MANUAL TRANSAXLE (M5GF2)
Lock Mode
Torque
Minimum
Base torque
ELQE501I
SCMMT6024L
MT -28 MANUAL TRANSAXLE (M5GF2)
C258
13 12 11 10
** ** 5 4 3
* 1
26 25 24 23 16 15 14
* 21 * * * *
SCMMT6012L
SCMMT6200L
TPS(or APS) signal which is used for judging driver’s intention is received from engine ECU through CAN line.
This signal is a criteria signal to determind amount of torque distribution at front/rear wheel with steering angle sensor,
wheel speed sensor, break signal.
SCMMT6201L
This code related to communication line between ECU and TCCU is set when CAN signal from ECU can’t received for
more than 1sec or ECU internal error occur.
If failure is detected TCCU prohibits the ITM control and cuts the current to control coil.
MT -30 MANUAL TRANSAXLE (M5GF2)
FIG.1)
SCMMT6202L
1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by
interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,or
damage.
YES
NO
3. Monitor signal waveform between terminal 4, 5 of TCCU harness connector and chassis ground.
4. Shift to N Range.
C258
13 12 11 10 * * * * 5 4 3 * 1
26 25 24 23 * 21 * * * * 16 15 14
4.CAN LOW
5.CAN HIGH
SCMMT6203L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Fault is intermittent caused by poor contact in the sensor’s and/or TCCU’s connector or was repaired and TCCU
memory was not cleared.Thoroughly check connectors for looseness, poor connection, bending, corrosion, contam-
ination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair"
procedure.
NO
3. Measure resistance between terminal "4" of the TCCU harness connector and terminal "5" of the TCCU harness
connector.
C258
13 12 11 10 * * * * 5 4 3 * 1
26 25 24 23 * 21 * * * * 16 15 14
4.CAN LOW
5.CAN
N HIGH
H
Ω
SCMMT6204L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Fault is intermittent caused by open or short in CAN signal harnessor was repaired and TCCU memory was not
cleared. Go to the applicable troubleshooting procedure.
NO
YES
NO
SCMMT6205L
Steering Wheel Angle Sensor installed in steering wheel prevents a state of TCB(Tight Corner Braking) by sensing the
rotating direction & straight driving of vehicle and is used for EMC duty control. In case of ESP system applied, 4WD
ECU receives this signal through CAN line. If it is not the case, 4WD ECU receives this signal from Steering Wheel Angle
Sensor directly.
※ TCB (Tight Corner Braking) : TCB is that the vehicle makes an abnormal noise and hesistation when the vehicle turns
left / right fully with low speed at a paved road.
SAS(STEERING
TCCU
ANGLE SENSOR)
SCMMT6206L
This code related to Steering Angle Sensor Signal( #1) is set when voltage of signal is above 4.5V or loss of signal is
occurred for more than 1sec. In case of ESP system applied, this code is set when can bus off or ecu enternal error is
occurred.
If failure is detected TCCU prohibits the ITM control and cuts the current to control coil.
MT -34 MANUAL TRANSAXLE (M5GF2)
FIG.1)
SCMMT6207L
1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by
interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,or
damage.
YES
NO
3. Monitor signal waveform between terminal 3 of Steering angle sensor harness connector and chassis ground.
M14
5.Center
6.Reference
2.Ground
6 5 4 3 2
* 4.S2
3.S1
SCMMT6208L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Fault is intermittent caused by poor contact in the sensor’s and/or TCCU’s connector or was repaired and TCCU
memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion, con-
tamination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair"
procedure.
NO
3. Measure voltage between terminal 6 of Steering angle sensor harness connector and chassis ground.
Specification : Approx. 5V
MT -36 MANUAL TRANSAXLE (M5GF2)
M14
5.Center
6.R
Refere
ence
2.Ground
6 5 4 3 2 4.S2
* 3.S1
SCMMT6209L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Go to " Steering angle sensor ground harness open circuit inspection " procedure.
NO
3. Measure resistance between terminal 2 of Steering angle sensor harness connector and chassis ground.
Specification : 1Ω below
M14
5.Center
6.Reference
2.Ground
6 5 4 3 2 4.S2
* 3.S1
SCMMT6210L
TRANSFER CASE ASSEMBLY MT -37
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Go to " Steering angle sensor #1 ,short to signal line ground Inspection " procedure.
NO
3. Measure resistance between terminal 3 of Steering angle sensor harness connector and chassis ground.
Specification : ∝ Ω
M14
5.Center
6.Reference
2.Ground
6 5 4 3 2 4.S2
* 3.S1
SCMMT6211L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Go to " Steering angle sensor #1 signal line open Inspection " procedure.
NO
▶ Check for short to ground circuit of Steering angle sensor #1Signal circuit.
▶ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
MT -38 MANUAL TRANSAXLE (M5GF2)
3. Measure resistance between terminal 3 of Steering angle sensor harness connector and terminal 23 of TCCU har-
ness connector.
Specification : 1Ω
C258
11.Center
13 12 11 10 * * * * 5 4 3 * 1 12.Ground
24.S2
26 25 24 23 * 21 * * * * 16 15 14 23.S1
25.Reference
Ω
M14 5.Center
6.Reference
2.Ground
4.S2
3.S1
6 5 4 3 2
*
SCMMT6212L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Substitute with a known-good TCCU or Steering angle sensor and check for proper operation.
▶ If the problem is corrected, replace TCCU and then go to "Verification of Vehicle Repair" procedure.
NO
YES
NO
This code related to Steering Angle Sensor Signal( #2) is set when voltage of signal is above 4.5V or loss of signal is
occurred for more than 1sec. In case of ESP system applied, this code is set when can bus off or ecu enternal error is
occurred.
If failure is detected TCCU prohibits the ITM control and cuts the current to control coil.
3. Monitor signal waveform between terminal 4 of Steering angle sensor harness connector and chassis ground.
M14
5.Center
6.Reference
2.Ground
6 5 4 3 2
* 4.S
S2
3.S1
SCMMT6213L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Fault is intermittent caused by poor contact in the sensor’s and/or TCCU’s connector or was repaired and TCCU
memory was not cleared.Thoroughly check connectors for looseness, poor connection, bending, corrosion, contam-
ination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair"
procedure.
NO
3. Measure resistance between terminal 4 of Steering angle sensor harness connector and chassis ground.
Specification : ∝ Ω
MT -42 MANUAL TRANSAXLE (M5GF2)
M14
5.Center
6.Reference
2.Ground
6 5 4 3 2 4.S
S2
* 3.S1
SCMMT6214L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Go to " Steering angle sensor #2, signal line open inspection " procedure.
NO
▶ Check for ground to short circuit of Steering angle sensor #2 Signal circuit.
▶ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
3. Measure resistance between terminal 4 of Steering angle sensor harness connector and terminal 24 of TCCU har-
ness connector.
Specification : 1Ω below
C258
11.Center
13 12 11 10 * * * * 5 4 3 * 1 12.Ground
24.S2
2
26 25 24 23 * 21 * * * * 16 15 14 23.S1
25.Reference
Ω
M14 5.Center
6.Reference
2.Ground
4.S2
3.S1
6 5 4 3 2
*
SCMMT6215L
TRANSFER CASE ASSEMBLY MT -43
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Substitute with a known-good TCCU or Steering angle sensor and check for proper operation.
▶ If the problem is corrected, replace TCCU and then go to "Verification of Vehicle Repair" procedure.
NO
This code related to Steering Angle Sensor Signal( #N) is set when voltage of signal is above 4.5V or loss of signal is
occurred for more than 1sec. In case of ESP system applied, this code is set when can bus off or ecu enternal error is
occurred.
If failure is detected TCCU prohibits the ITM control and cuts the current to control coil.
FIG.1)
SCMMT6250L
TRANSFER CASE ASSEMBLY MT -45
3. Monitor signal waveform between terminal 5 of Steering angle sensor harness connector and chassis ground.
M14
5.Center
6.Reference
2.Ground
6 5 4 3 2
* 4.S2
3.S1
SCMMT6217L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Fault is intermittent caused by poor contact in the sensor’s and/or TCCU’s connector or was repaired and TCCU
memory was not cleared.Thoroughly check connectors for looseness, poor connection, bending, corrosion, contam-
ination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair"
procedure.
NO
3. Measure resistance between terminal 5 of Steering angle sensor harness connector and chassis ground.
Specification : ∝ Ω
M14
5.Center
6.Reference
2.Ground
6 5 4 3 2
* 4.S2
3.S1
SCMMT6218L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
NO
▶ Check for ground to short circuit of Steering angle Neutral Signal circuit.
▶ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
3. Measure resistance between terminal 3 of Steering angle sensor harness connector and terminal 23 of TCCU har-
ness connector.
Specification : 1Ω below
TRANSFER CASE ASSEMBLY MT -47
C258
11.Ce
enter
13 12 11 10 * * * * 5 4 3 * 1 12.Ground
24.S2
26 25 24 23 * 21 * * * * 16 15 14 23.S1
25.Reference
Ω
M14 5.Center
6.Reference
2.Ground
4.S2
3.S1
6 5 4 3 2
*
SCMMT6219L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Substitute with a known-good TCCU or Steering angle sensor and check for proper operation.
▶ If the problem is corrected, replace TCCU and then go to "Verification of Vehicle Repair" procedure.
NO
▶ Check for open circuit of Steering angle sensor Neutral Signal circuit.
▶ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
SCMMT6220L
Vehicle uses 2WD(2 wheel drive) for driving at normal speed, but sometimes it uses 4WD (4 wheel drive) accordign to
driving condition.
(cornering or acceleration)
EMC(Electric Magnetic Clutch) distributes proper torque to front wheel by controling amount of current inside EMC coil.
That time power pressing the multi plate clutch by apply cam is changed by a rate of EMC duty. after multi plate clutch
start slip the force for acceletion at front/rear wheel is controlled at a range of 100:0 ~ 50 : 50.
ITM system has 4WD-LOCK function that can make driving force to 50:50 by compulsion according to driver’s intention.
1. COIL
2. ROTOR
3. PRIMARY CLUTCH
4. AFLY CAM
5. SECONDARY CLUTCH
SCMMT6221L
This DTC code is related to the EMC and is set If control harness has an open or short to battery source.
If failure is detected TCCU prohibits the ITM control and vehicle is controlled with 2WD by intercepting EMC current.
TRANSFER CASE ASSEMBLY MT -49
FIG.1) FIG.2)
1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by
interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,or
damage.
YES
NO
3. Monitor signal waveform between terminal 1 of EMC harness connector and chassis ground.
4. Shift to N Range.
F09
1.EMC Output
2 1 2.EMC Ground
SCMMT6223L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Fault is intermittent caused by poor contact in the sensor’s and/or TCCU’s connector or was repaired and TCCU
memory was not cleared.Thoroughly check connectors for looseness, poor connection, bending, corrosion, contam-
ination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair"
procedure.
NO
3. IG "ON.
4. Measure voltage between terminal 1 of EMC harness connector and chassis ground.
Specification : 0 V
TRANSFER CASE ASSEMBLY MT -51
F09
1.EMC Output
2 1 2.EMC Ground
SCMMT6224L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
NO
3. Measure resistance between terminal 1 or 2 of Electric Magnet Valve Clutch harness connector and terminal 26 or
13 of TCCU harness connector.
Specification : 1Ω below
MT -52 MANUAL TRANSAXLE (M5GF2)
C258
13 12 11 10 * * * * 5 4 3 * 1 13.EMC Ground
26 25 24 23 * 21 * * * * 16 15 14 26.EM
MC Outtput
F09
1.EMC
C Outp
put
2.EMC Ground
2 1
SCMMT6225L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
NO
3. Measure the resistance(Component side) between terminals "1" and "2" of the "Electric Magnet Valve Clutch".
F09
1.EMC
C Outpu
ut
1 2 2.EMC
C Groun
nd
SCMMT6226L
YES
▶ Substitute with a known-good "TCCU" and check for proper operation. If the problem is corrected, replace "TCCU"
and then go to "Verification of Vehicle Repair" procedure.
NO
▶ Substitute with a known-good "EMC coil" and check for proper operation. If the problem is corrected, replace
"EMC coil" and then go to "Verification of Vehicle Repair" procedure.
YES
NO
SCMMT6227L
Many control units is applied to the vehicle due to vehicle to be electronic control type and these perform many controls by
receiving signals from sensors. So the common use of each sensors and the need of comunizing informations became a
prominent figure. CAN comunication method is used at power train (ABS, trnasmission, engine, ECS etc) control of vehicle
because it withstands eletronical external noise by spark and can high-speed comunication. Though CAN communication,
ECM and TCM hold engin RPM, APS, step of trensmission, decreasing of torque in common and perform the active
control.
SCMMT6228L
SCMMT6229L
YES
▶ Check if equipped option(ABS/TCS, ESP) and part number is qualified specification Repair or replace as neces-
sary and go to "Verification of vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by poor contact in the sensor’ s and/or TCCU’ s connector or was repaired and
TCCU memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification of vehicle Repair"
procedure.
YES
NO
SCMMT6251L
Wheel Speed Sensor senses vehicle speed and difference between front and rear wheel speed.
Opreation for getting Rotating Speeds of front/rear wheel can be got from deviding wheel speed sensor Rotating Speeds
of front/rear by 2.
In case of ESP(or FTCS) system applied 4WD ECU receives this signal through CAN line, If it is not the case 4WD ECU
receives this signal directly by using PWM communication line.
The wheel speed sensor is the essential component the ITM ECU uses to determine how to distribute driving force to
front / rear wheel with steering angle sensor signal and TPS, brake signal.
SCMMT6201L
This code related to communication line between ECU and TCCU is set when CAN signal from ECU can’t received for
more than 1sec or ECU internal error occur.
If failure is detected TCCU prohibits the ITM control and cuts the current to control coil.
MT -58 MANUAL TRANSAXLE (M5GF2)
FIG.1)
SCMMT6202L
1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by
interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,or
damage.
YES
NO
3. Monitor signal waveform between terminal 4, 5 of TCCU harness connector and chassis ground.
4. Start and drive vehicle in gear and maintain vehicle speed approx. 10km/h or less(6mph or less).
C258
13 12 11 10 * * * * 5 4 3 * 1
26 25 24 23 * 21 * * * * 16 15 14
4.CAN LOW
5.CAN HIGH
SCMMT6203L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Fault is intermittent caused by poor contact in the sensor’s and/or TCCU’s connector or was repaired and TCCU
memory was not cleared.Thoroughly check connectors for looseness, poor connection, bending, corrosion, contam-
ination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair"
procedure.
NO
3. Measure resistance between terminal "4" of the TCCU harness connector and terminal "5" of the TCCU harness
connector.
C258
13 12 11 10 * * * * 5 4 3 * 1
26 25 24 23 * 21 * * * * 16 15 14
4.CAN LOW
5.CAN
N HIGH
H
Ω
SCMMT6204L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Fault is intermittent caused by open or short in CAN signal harnessor was repaired and TCCU memory was not
cleared. Go to the applicable troubleshooting procedure.
NO
YES
NO
ITM(InterActive Torque Management) system can detect the tire size fault by calculating each wheel speed, if the tire size
equipped at the vehicle is 10% bigger than normal tire.
Wheel Speed Sensor senses vehicle speed and difference between front and rear wheel speed.
Opreation for getting Rotating Speeds of front/rear wheel can be got from deviding wheel speed sensor Rotating Speeds
of front/rear by 2
This code is set, if ITM-ECU detect tha the tire size is 10% bigger than normal tire by calculating each wheel speed.
When the failure is set there is no signal in the warning lamp, just ITM-ECU sets and stores this code.
SCMMT6232L
YES
NO
▶ Fault is intermittent caused by poor contact in the sensor’ s and/or TCCU’ s connector or was repaired and
TCCU memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace asnecessary and go to "Verification of vehicle Repair"
procedure .
YES
NO
SCMMT6233L
Vehicle uses 2WD(2 wheel drive) for driving at normal speed, but sometimes it uses 4WD (4 wheel drive) accordign to
driving condition.
(cornering or acceleration)
EMC(Electric Magnetic Clutch) distributes proper torque to front wheel by controling amount of current inside EMC coil.
That time power pressing the multi plate clutch by apply cam is changed by a rate of EMC duty. after multi plate clutch
start slip the force for acceletion at front/rear wheel is controlled at a range of 100:0 ~ 50 : 50.
ITM system has 4WD-LOCK function that can make driving force to 50:50 by compulsion according to driver’s intention.
1. COIL
2. ROTOR
3. PRIMARY CLUTCH
4. AFLY CAM
5. SECONDARY CLUTCH
SCMMT6221L
When the failure is set there is no signal in the warning lamp, just ITM-ECU sets and stores this code.
If the ITM-ECU decides that the clutch(EMC) and oil are over-heated (above specified value) for more than 1s.
When the failure is set there is no signal in the warning lamp, just ITM-ECU sets and stores this code.
MT -64 MANUAL TRANSAXLE (M5GF2)
SCMMT6253L
YES
NO
▶ Fault is intermittent caused by poor contact in the sensor’ s and/or TCCU’ s connector or was repaired and
TCCU memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace asnecessary and go to "Verification of vehicle Repair"
procedure.
TRANSFER CASE ASSEMBLY MT -65
YES
NO
Many control units is applied to the vehicle due to vehicle to be electronic control type and these perform many controls by
receiving signals from sensors. So the common use of each sensors and the need of comunizing informations became a
prominent figure. CAN comunication method is used at power train (ABS, trnasmission, engine, ECS etc) control of vehicle
because it withstands eletronical external noise by spark and can high-speed comunication. Though CAN communication,
ECM and TCM hold engin RPM, APS, step of trensmission, decreasing of torque in common and perform the active
control.
This code is set, if ITM-ECU detects invailid engine information like engine displacement, torque.
If failure is detected TCCU prohibits the ITM control and cuts the current to control coil.
SCMMT6237L
YES
NO
▶ Fault is intermittent caused by poor contact in the sensor’ s and/or TCCU’ s connector or was repaired and
TCCU memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace asnecessary and go to "Verification of vehicle Repair"
procedure.
YES
NO
SCMMT6238L
CAN communication is a parallel circuit to interchange information among each units. CAN communication can share
much information with units more faster and more efficiently by using specified language.
CAN-High line is twisted with CAN-Low line as a purpose in preventing from a noise.
ITM-ECU performs active control by sharing signals of engine RPM, APS, shift position, torque reduction.
SCMMT6201L
This code related to communication line between ECU(PCU, ABS, ESP) and TCCU is set when CAN signal from ECU
can’t received for more than 1sec or ECU internal error occur.
If failure is detected TCCU prohibits the ITM control and cuts the current to control coil.
TRANSFER CASE ASSEMBLY MT -69
FIG.1)
SCMMT6202L
1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by
interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,or
damage.
YES
NO
3. Monitor signal waveform between terminal 4, 5 of TCCU harness connector and chassis ground.
4. Shift to N Range.
C258
13 12 11 10 * * * * 5 4 3 * 1
26 25 24 23 * 21 * * * * 16 15 14
4.CAN LOW
5.CAN HIGH
SCMMT6203L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Fault is intermittent caused by poor contact in the sensor’s and/or TCCU’s connector or was repaired and TCCU
memory was not cleared.Thoroughly check connectors for looseness, poor connection, bending, corrosion, contam-
ination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair"
procedure.
NO
3. Measure resistance between terminal "4" of the TCCU harness connector and terminal "5" of the TCCU harness
connector.
C258
13 12 11 10 * * * * 5 4 3 * 1
26 25 24 23 * 21 * * * * 16 15 14
4.CAN LOW
5.CAN
N HIGH
H
Ω
SCMMT6204L
CAUTION
The above value is only for reference.
The actual value may differ from it according to various engine condition.
YES
▶ Fault is intermittent caused by open or short in CAN signal harnessor was repaired and TCCU memory was not
cleared. Go to the applicable troubleshooting procedure.
NO
YES
NO
TRANSFER CASE
COMPONENTS E5DB3362
INSPECTION E046DF3C
REPLACEMENT E6E243DF
[DIESEL 2.2L]
5. Remove the RH driveshaft (see ’DS’ group-’DRIVE- 9. Remove the transfer case assembly by removing the
SHAFT’). mounting bolts(A-6ea).
SCMMT6029L
TRANSFER CASE ASSEMBLY MT -79
[GASOLINE 2.7L] 7. Drain the transfer oil through drain plug hole.
A
1. Remove the battery negative (-) cable.
SCMMT6027L
B
9. Remove the heat protector(A) using a hexagonal
socket.
NOTE
To remove the heat protector mounting bolt easily, be-
fore removing the heat protector mounting bolts(3EA),
apply the mounting bolt with "WD-40 stops squeaks".
A
SCMMT6025L
NOTE
To remove the exhaust manifold mounting nut easily,
before removing the exhaust manifold mounting
nuts(7EA), apply the mounting nuts with "WD-40
stops squeaks".
14. Using a flat head screw driver, remove the transfer 4. Remove the transfer cover(A).
from the transaxle by moving the driver to left and right
directions.
A
DISASSEMBLY E1E594D1
NOTE
This assembly can be removed with a propella shaft
assembly in ’REMOVAL’ step.
SCMMT6077D
SCMMT6070D
SCMMT6072D
NOTE
When reassembling the transfer, be sure to always
replace the oil seal(47452-39000) with new part.
SCMMT6071D
TRANSFER CASE ASSEMBLY MT -81
NOTE
A When reassembling the transfer, be sure to always
replace the oil seal(47350-39300) with new part.
SCMMT6073D
SCMMT6076D
REASSEMBLY E6E29444
NOTE
1. Clean all parts except the taper roller bearings.
B
Be careful about the direction of seals.
2. Oil bearings with hypoid gear oil API GL5.
3. Smear involute splines all covering with high
pressure grease "Klueber microlube GNY202".
SCMMT6074D 4. Measuring temperature: 20 ±5 C.
5. O-ring has to be dipped into hypoid gear oil API
GL5. Allow excess oil to drain.
6. Contact surface of the transfer housing to be
C
coated with "SEALANT 732" or equivalent
(silicon type sealing agent) prior to mounting.
Coating thickness: 0.1mm MIN. Prior to coating,
mating surfaces must be clean and free from oil
and grease.
7. Transfer oil specification : Hypoid gear oil "API
GL5, SAE 75W/90 SHELL SPIRAX EQUIVA-
A LENT". Filled up to lower filler plug thread level(
Approx. 0.8L)
8. The hypoid gear set must be managed as a
pair. Whenever installing or replacing a hypoid
gear shaft assembly(47339-39300) or a pinion
SCMMT6075D shaft(47311-39300). Make sure to install or
replace as a pair.
9. Remove the oil seal(A) from the transfer cover. 9. In reassembling, refer to the two figures below.
MT -82 MANUAL TRANSAXLE (M5GF2)
SCMMT6042D
1. Install the transfer drive gear with the taper roller Corresponding preload torque(measured without
bearings(47366-39000 and 47465-39000) into trans- seals) : 120 to 180Ncm.
fer housing.
PART NUMBER SPACER THICKNESS (mm)
2. Applying the preload(100 to 200N) to bearings, mea-
sure the dimension J. 47383-39152 1.520-1.539
47383-39154 1.540-1.559
3. Measure the dimension H on transfer cover(47314-
39200). 47383-39156 1.560-1.579
47383-39158 1.580-1.599
4. Select the spacer thickness from the chart below.
Thickness S4= H-J+K. (K: Bearing preload = 0.07 to 47383-39160 1.600-1.619
0.11mm. )
TRANSFER CASE ASSEMBLY MT -83
SPACER 15. Install the hypoid gear shaft assembly(A) and the
PART NUMBER transfer drive gear assembly(B) in the transfer hous-
THICKNESS(mm)
ing.
47384-39218 2.180-2.199
47384-39220 2.200-2.219
47384-39222 2.220-2.239
A
47384-39224 2.240-2.259
47384-39226 2.260-2.279
47384-39228 2.280-2.299
B
47384-39230 2.300-2.319
47384-39232 2.320-2.339
47384-39234 2.34-2.37
47384-39238 2.38-2.41
47384-39242 2.42-2.45
47384-39246 2.46-2.49
47384-39250 2.50-2.53
SCMMT6072D
8. Install the spacer selected above, the taper roller 16. Measure the dimension F.
bearings and the hypoid gear shaft assembly F…. Assembled dimension of pinion assembly.
(47339-39300). And preload the assembly without G…. Finished dimension of transfer hous-
the spacer(Hypoid gear shaft assembly-Transfer ing.(=88.0mm)
cover side) with 100 to 200N. E…. Mounting distance(=69.500 ± deviation).
9. Measure the dimension L after 10 rotations.
17. Select the spacer thickness from the chart below.
Thickness S1=E+F-G
10. Measure the dimension M on transfer cover (47314-
39300).
NOTE
11. Select the spacer thickness from the chart above in If it is not possible to reach the exact mounting dis-
the step 7. Thickness S3=M-L+(0.09 to 0.12mm) tance, select the next thinner spacer S1.
preload.
SPACER
12. Install the spacer selected above. PART NUMBER
THICKNESS(mm)
13. Install the taper roller bearing outer races to the trans- 47385-39125 1.25-1.28
fer housing and cover. 47385-39129 1.29-1.32
14. Install a new oil seal(A) in the transfer housing. 47385-39133 1.33-1.36
47385-39137 1.37-1.40
47385-39141 1.41-1.44
A
47385-39145 1.45-1.48
47385-39149 1.49-1.52
47385-39153 1.53-1.56
47385-39157 1.57-1.60
47385-39161 1.61-1.64
47385-39165 1.65-1.68
47385-39169 1.69-1.72
47385-39172 1.720-1.739
47385-39174 1.740-1.759
SCMMT6073D
TRANSFER CASE ASSEMBLY MT -85
SPACER SPACER
PART NUMBER PART NUMBER
THICKNESS(mm) THICKNESS(mm)
47385-39176 1.760-1.779 47385-39208 2.080-2.099
47385-39178 1.780-1.799 47385-39210 2.100-2.119
47385-39180 1.800-1.819 47385-39213 2.13-2.16
47385-39182 1.820-1.839 47385-39217 2.17-2.20
47385-39184 1.840-1.859 47385-39221 2.21-2.24
47385-39186 1.860-1.879 47385-39225 2.25-2.28
47385-39188 1.880-1.899 47385-39229 2.29-2.32
47385-39190 1.900-1.919 47385-39233 2.33-2.36
47385-39192 1.920-1.939
18. Install the pinion assembly with the selected spacer
47385-39194 1.940-1.959
above and measure the circumference backlash on
47385-39196 1.960-1.979 pinion.
47385-39198 1.980-1.999 (Measuring diameter, backlash and permissible devi-
ations for measurement on pinion, see table below).
47385-39200 2.000-2.019 If the result is out of permissible range, change the
47385-39202 2.020-2.039 spacer thickness S2, then start again with the step
8~12).
47385-39204 2.040-2.059
47385-39206 2.060-2.079
TIPS FOR SPACER ADJUSTMENT FOR HYPOID GEAR BACKLASH AND CONTACT PATTERN
• Normal state
• Standard tooth pattern
- Both drive and coast surfaces are in
center in lateral direction and slightly
incline to TOE side in vertical direction
Drive Coast
• If the pattern deviates from the standard,
adjust it by following procedure
UMQG004D
Hypoid gear tooth
contacy pattern • Abnormal state
• The dirve surface inclines to TOE and
TOP and the coast surface inclines
to HEEL and TOP
19. Remove the pinion assembly. With the spacer S3 INSTALLATION E5F331AD
NOTE A
1. Before installing the pinion assembly, check the
pinion O-ring and apply the oil to the O-ring.
2. To make the installation of the pinion to the trans-
fer easier, tap the pinion using a plastic hammer
after aligning the bolt holes.
B
A
SCMMT6063D
[GASOLINE 2.7L]
SCMMT6070D
NOTE
To install the transfer easily, install it by moving the
pinion left and right directions, and slightly rotating the
inner drive shaft of transfer assembly.
TORQUE:
62~67 Nm(6.2~6.7 kgf.m, 44.8~48.5 lb-ft)
TORQUE:
47~51 Nm(4.7~5.1 kgf.m, 34.0~36.9 lb-ft) - 2EA
24~28 Nm(2.4~2.8 kgf.m, 17.4~20.3 lb-ft) - 2EA
TRANSFER CASE ASSEMBLY MT -87
4. Tighten the exhaust manifold mounting nuts(7EA). 8. Install the front exhaust pipe assembly(A).
TORQUE:
30~35 Nm(3.0~3.5 kgf.m, 21.7~25.3 lb-ft)
TORQUE:
11.8~14.7 Nm(1.2~1.5 kgf.m, 8.7~10.8 lb-ft)
A
SCMMT6022L
UMQG002K
11. Install the engine side cover (RH) and the wheel and
tire(RH).
6. Tighten the pinion case mounting bolts(6EA).
12. Install the oxygen sensor connector bracket and con-
TORQUE: nect the oxygen sensor connector(A,B). (Engine room
37~40 Nm(3.7~4.0 kgf.m, 14.5~21.7 lb-ft) right side).
SCMMT6027L SCMMT6025L
7. Refill the transfer oil through the filler plug. 13. Connect the battery negative (-) cable.
MT -88 MANUAL TRANSAXLE (M5GF2)
COMPONENTS EA0B2C67
SCMMT6013L
TRANSFER CASE ASSEMBLY MT -89
1. Remove the oil seal(A) from the transfer drive gear. 1. Using a press machine, install the taper roller bear-
ings(A) to the transfer drive gear.
UMQG006B
UMQG006F
2. Using the SST(09455-21000), remove the taper roller
bearings(A) from the both sides of the transfer drive
gear assembly.
09455-21000
UMQG006C
09455-21000
UMQG006D
MT -90 MANUAL TRANSAXLE (M5GF2)
HYPOID GEAR
COMPONENTS EDEC1CEB
1. Using the SST(09455-21000), remove the taper roller 1. Using a press machine, install the taper roller bear-
bearing(A) from the hypoid gear shaft assembly. ings(A) to the hypoid gear shaft assembly.
A
A
UMQG007C UMQG007F
09455-21000
UMQG007G
UMQG007D
UMQG007E
MT -92 MANUAL TRANSAXLE (M5GF2)
COMPONENTS E3FABF07
SCMMT6081D
09455-32200
UMQG005F
UMQG005C
6. Using a press machine, remove the pinion shaft(A)
3. Loosen the HEX lock nut(A). from the pinion case(B).
SCMMT6080D UMQG005G
MT -94 MANUAL TRANSAXLE (M5GF2)
7. Take out the taper roller bearing(A) from the pinion REASSEMBLY E546DB0B
case(B).
1. Assemble the taper roller bearing outer races.
UMQG005H
B
8. Using a sliding hammer(A), remove the taper roller
bearing outer race(B) from the pinion case(C).
UMQG005J
UMQG005I
UMQG005K
SCMMT6080D
TRANSFER CASE ASSEMBLY MT -95
F1
F2
UMQG005L
CAUTION
If the permissible preload torque of 210Ncm is ex-
ceeded, it is not allowed to loosen Hex lock nut.
Disassemble the whole pinion assembly. Replace
the collapsible spacer and repeat the mounting
procedure.
COUPLING ASSEMBLY
COMPONENTS EC967608
1
Steel balls (6EA)
2
8
3
4 9
Secondary clutch 10
5
11
12
Disk (10EA)
Plate
(10EA)
13
14
15
16
6 17
18
19
20
7
C KKQE010C
C A B SCMMT6016L
KKQE009C SCMMT6064D
MT -98 MANUAL TRANSAXLE (M5GF2)
6. Using a flat tool(A), separate the 4WD coupling as- 3. Remove the coupling flange oil seal(A).
sembly(B) from the rear differential carrier(C).
A
KKQE016C
KKQE012C
4. Using a general tool, 3-way puller(A), remove the
7. Remove the 4WD coupling assembly(A). flange assembly(B) from the coupling(C).
DISASSEMBLY E50DFC6F
A C
KKQE014C EKQE017C
KKQE015C
TRANSFER CASE ASSEMBLY MT -99
5. Remove the flange oil seal(A) using special tool 2) Remove the snap ring.
(09432-33200).
3) Remove the Electric Magnetic clutch(B) mount-
ing nuts (A-3EA).
09432
-33200
EKQE018C
0.8~1.1kgf m
KKQE019C
NOTE
Insert the (-) driver between the oil seal and the clutch
housing, then remove the oil seal
A B
KKQE022C
KKQE020C
MT -100 MANUAL TRANSAXLE (M5GF2)
7. Remove the wave spring(B) for fixing the back 10. Remove the back plate and the secondary clutch(A)
plate(A) and the secondary clutch assembly. assembly simultaneously using special tool (09478-
26100).
B
09478-26100
A
KKQE023C
KKQE026C
8. Remove the snap ring(A).
1) Separate the back plate(A) from the input shaft.
KKQE024C
KKQE027C
9. After removing the oil seal, remove the snap ring(A).
2) Remove the plates (A-10EA) and the discs
(B-10EA).
A
B
KKQE025C
KKQE028C
TRANSFER CASE ASSEMBLY MT -101
A A
KKQE029C KKQE032C
A
A
KKQE030C KKQE033C
11. Remove the steel balls (A-6EA) on the base cam. 14. Remove the thrust race.
A
A
KKQE031C KKQE034C
REASSEMBLY EBAA23A8
A
1. When reassembling the back plate oil seal(A), re-
assemble it using a suitable tool(B).
KKQE035C
A KKQE038C
A
KKQE036C
A
KKQE039C
KKQE037C
NOTE
Additionally remove each 2EA discs and plates alter-
nately.
TRANSFER CASE ASSEMBLY MT -103
EKQE040C
09478-26000
KKQE041C
INSTALLATION E0B9AE32