MTMANUAL TRANSMISSION GENERAL 1. SPECIFICATIONS. 1) General Specifications. 2) Tightening Torque MANUAL TRANSMISSION

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1 03-3 MT GENERAL 1. SPECIFICATIONS 1) General Specifications 2) Tightening Torque

03-4 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW 4WD Features 1. All gears use the helical type and high strength materials.

To prevent the double engagement, the independent interlock devices are installed. 1.

It provides maximum drivability by the optimized engine torque and gear ratio. 2. TSM54/52 transmission uses linkage type shift elements directly connected to the transmission.

2 03-4 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW 4WD Features 1. All gears use the helical type and high strength materials. 2WD (Gasoline) The helical type gear prevents the axial gear missing and provides less noise. 2. The synchronizing devices are installed in 1/2, 3/4, 5/R gears. To prevent the double engagement, the independent interlock devices are installed. 1. TSM54/52 transmission is designed to link the gearratio, installation dimensions and shapes with current T5 transmission and BTRA automatic transmission. It provides maximum drivability by the optimized engine torque and gear ratio. 2. TSM54/52 transmission uses linkage type shift elements directly connected to the transmission. It prevent the transmission from shifting to the reverse gear from 5th gear when shifting to reverse gear. It also prevents the break and wear. TSM54/52 transmission uses the inertia lock type key to make smooth gear engagement and to provide silent gear engagement. 3. The clutch release system is available to use CSC (Concentric Slave Cylinder) or Fork type according to the vehicle model. New Rexton uses the fork type clutch release system. 4. The semi-remote control type gear shift mechanism is used to prevent incorrect shifting.

3 SYSTEM COMPONENTS 1) Gear Combinations 2) Shift Fork and Rail Combinations

4 03-6 3) Sectional View

5 Transmission front housing 2. Input shaft oil seal 3. Front cover 4. Hexagon flange bolt (17 ~ 26 Nm) 5. Oil drain plug 6. Sealing 7. Pin 8. Input shaft 9. Clutch 4th gear 10. Taper roller bearing (main) 11. Taper roller bearing 12. Counter shaft 13. Taper roller bearing (counter) 14. Output shaft 15. Inner race (reverse) 16. Inner race (1st) 17. Needle bearing 18. 1st gear 19. 1st clutch gear 20. Synchro outer ring 21. Synchro - middle cone 22. Synchro inner ring 23. Synchro spring 24. Synchro key 25. Synchro hub 26. Double synchro sleeve 27. 2nd gear 28. 3rd gear 29. 3rd clutch gear 30. Synchro hub (3 & 4th) 31. Synchro ring (4/5/R) 32. Single synchro sleeve 33. Retainer ring 34. Adaptor dowel pin 35. Reverse idler shaft 36. Dowel pin 37. Needle bearing 38. Reverse idler gear 39. Reverse idler spacer 40. Reverse idler bracket 41. Retainer ring 42. Reverse lock nut 43. Transmission adaptor 44. Input shaft spacer 45. Counter spacer 46. Reverse needle bearing 47. Reverse gear 48. Reverse clutch gear 49. Reverse counter gear 50. Synchro hub 51. Counter 5th gear 52. 5th needle bearing 53. 5th gear 54. 5th clutch gear 55. Thrust washer 56. Spring pin 57. 5th outside retainer ring 58. 5th retainer ring 59. Counter shaft bushing 60. Counter roller bearing assembly 61. Retainer ring 62. Extension housing 63. Output shaft oil seal 64. Offset plate 65. Counter screw 66. Top cover 67. Counter oil seal 68. Shift shaft 69. Shift lever 70. Detent pin 71. Joint pin 72. Retainer ring 73. Semi remote lever assembly

6 03-8 IDI Engine equipped vehicle - 4WD

7 Transmission front housing 2. Input shaft oil seal 3. Front cover 4. Hexagon flange bolt (17~26 Nm) 5. Oil drain plug 6. Sealing 7. Pin 8. Input shaft 9. Clutch 4th gear 10. Taper roller bearing (main) 11. Taper roller bearing 12. Counter shaft 13. Taper roller bearing (counter) 14. Output shaft 15. Inner race (reverse) 16. Inner race (1st) 17. Needle bearing 18. 1st gear 19. 1st clutch gear 20. Synchro outer ring 21. Synchro - middle cone 22. Synchro inner ring 23. Synchro spring 24. Synchro key 25. Synchro hub 26. Double synchro sleeve 27. 2nd gear 28. 3rd gear 29. 3rd clutch gear 30. Synchro hub (3 & 4th) 31. Synchro ring (4/5/R) 32. Single synchro sleeve 33. Retainer ring 34. Adaptor dowel pin 35. Reverse idler shaft 36. Dowel pin 37. Bearing 38. Reverse idler gear 39. Reverse idler spacer 40. Reverse idler bracket 41. Retainer ring 42. Reverse lock nut 43. Transmission adaptor 44. Input shaft spacer 45. Counter spacer 46. Reverse needle bearing 47. Reverse gear 48. Reverse clutch gear 49. Reverse counter gear 50. Synchro hub 51. Counter 5th gear 52. 5th needle bearing 53. 5th gear 54. 5th clutch gear 55. Thrust washer 56. Spring pin 57. 5th outside retainer ring 58. 5th retainer ring 59. Counter shaft bushing 60. Counter roller bearing assembly 61. Retainer ring 62. Extension housing 63. Output shaft oil seal 64. Offset plate 65. Counter screw 66. Top cover 67. Counter oil seal 68. Shift shaft 69. Shift lever 70. Detent pin 71. Joint pin 72. Retainer ring 73. Semi remote lever assembly 74. Rear flange

8 03-10 IDI Engine equipped vehicle - 2WD

9 Transmission front housing 2. Input shaft oil seal 3. Front cover 4. Hexagon flange bolt (17 ~ 26 Nm) 5. Oil drain plug 6. Sealing 7. Pin 8. Input shaft 9. Clutch 4th gear 10. Taper roller bearing (main) 11. Taper roller bearing 12. Counter shaft 13. Taper roller bearing (counter) 14. Output shaft 15. Inner race (reverse) 16. Inner race (1st) 17. Needle bearing 18. 1st gear 19. 1st clutch gear 20. Synchro outer ring 21. Synchro - middle cone 22. Synchro inner ring 23. Synchro spring 24. Synchro key 25. Synchro hub 26. Double synchro sleeve 27. 2nd gear 28. 3rd gear 29. 3rd clutch gear 30. Synchro hub (3 & 4th) 31. Synchro ring (4/5/R) 32. Single synchro sleeve 33. Retainer ring 34. Adaptor dowel pin 35. Reverse idler shaft 36. Dowel pin 37. Bearing 38. Reverse idler gear 39. Reverse idler spacer 40. Reverse idler bracket 41. Retainer ring 42. Reverse lock nut 43. Transmission adaptor 44. Input shaft spacer 45. Counter spacer 46. Reverse needle bearing 47. Reverse gear 48. Reverse clutch gear 49. Reverse counter gear 50. Synchro hub 51. Counter 5th gear 52. 5th needle bearing 53. 5th gear 54. 5th clutch gear 55. Thrust washer 56. Spring pin 57. 5th outside retainer ring 58. 5th retainer ring 59. Counter shaft bushing 60. Counter roller bearing assembly 61. Retainer ring 62. Extension housing 63. Output shaft oil seal 64. Offset plate 65. Counter screw 66. Top cover 67. Counter oil seal 68. Shift shaft 69. Shift lever 70. Detent pin 71. Joint pin 72. Retainer ring 73. Semi remote lever assembly 74. Rear flange 75. Ball bearing 76. Lock nut

10 ) Front View and Rear View Front view Rear view 1. Oil filler plug (tightening torque: 40 ~ 50 Nm) 2. Shift rug (3 & 4th) 3. Spring pin (6 x 25) 4. Shift rug (5 & reverse) 5. Shift rail (5 & reverse) 6. Backup lamp switch (tightening torque: 30 ~ 40 Nm) 7. Shift rail (3 & 4th) 8. Interlock bolt (tightening torque: 40 ~ 50 Nm) 9. Shift lever 10. Interlock plate 11. Shift rail (1 & 2nd) 12. Shift rug (1& 2nd) 13. Shift fork (3 & 4th) 14. Input shaft 15. Counter shaft 16. Reverse idler assembly 17. Spring pin (6 x 25) 18. Spring pin (6 x 25) 19. Backup lamp switch 20. Concentric slave cylinder adaptor (8) Apply Loctite 243 (6) Apply Loctite DRI LOC 200

11 ) Cross Sectional Diagram of Major Components Shift rail and 5/R gear Offset lever 1. Reverse lock spring 2. Reverse lock plate 3. Reverse lock bolt 4. Stopper plate 5. Air vent (tightening torque: 30 ~ 40 Nm) 6. Lock washer 7. TGS bushing 8. Outer spring pin 9. TGS pin 10. Lock bolt (tightening torque: 17 ~ 26 Nm) 11. Offset lever 12. Offset lever bushing 13. Rolling plunger 14. Return spring 15. Spring plug (tightening torque: 30 ~ 35 Nm) A. Apply Long-term grease MoS2 when installing the offset lever.

12 ) Power Flows 1st gear Counter shaft 2nd gear

13 ) Power Flows (Cont'd) 3rd gear 4th gear

14 ) Power Flows (Cont'd) 5th gear Reverse gear

15 SHIFTING MECHANISM 1) Interlock System Interlock system prevents the gears from meshing over two sets. 2) Reverse Interlock System Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward.

03-18 3) Offset Lever and Rolling Plunger To make the next shift easier, the offset lever applies a reaction force to shift lever toward center position of

16 ) Offset Lever and Rolling Plunger To make the next shift easier, the offset lever applies a reaction force to shift lever toward center position of gear selection gate after a gear has been selected. 1. Offset lever 2. Shift lever 3. Shift shaft 4. Rolling plunger (rolling plunger return spring and ball)

17 Shift check device It determines the shift fork position (N or each gear) and gives a detent movement to notice a shift lever seating when operating the shift lever. Also, it prevent the selected gear from getting out of its meshed position. 2. Gear pump out locking device It prevents the shift lever is beyond the correct shift position while shifting. 3. Guiding a control direction and preventing an over stroke 4) Backup Lamp Switch It is normal open type switch. Its circuit is formed when the reverse gear is selected. - - Sealant: Loctite DRI LOC 200 Tightening torque: 3 kg.m ~ 4 kg.m

03-20 5) Synchronizer Composition It consists of synchronizer hub, sleeve, ring, key and spring

- - 3/4 and 5/R shift: Single cone type 1/2 shift: Double cone type - Improving the capacity to

Double cone type 1/2 shift 3/4 shift 5/R shift 1/2 shift 3/4 shift 5/R shift 1.Synchronizer sleeve 2.

18 ) Synchronizer Composition It consists of synchronizer hub, sleeve, ring, key and spring (1/2, 5/R, and 3/4 synchronizer are different from each other) /4 and 5/R shift: Single cone type 1/2 shift: Double cone type - Improving the capacity to bigger engine torque of 1/2 shift (added synchronizer inner cone and middle cone) Single cone type Double cone type 1/2 shift 3/4 shift 5/R shift 1/2 shift 3/4 shift 5/R shift 1.Synchronizer sleeve 2. Synchronizer hub 3. Synchronizer ring 4. Synchronizer key 5. Synchronizer key locking ring 6. Synchronizer inner cone 7. Synchronizer middle cone Be careful not to mix up the 1/2 shift synchronizer sleeve with 3/4 or 5/R shift synchronizer sleeve. The 3/4 synchronizer hub also different from 1/2 and 5/R synchronizer hub (different oil gallery).

19 03-21 Synchronizer element A cone or sleeve that slides to and fro on the transmission main shaft and makes the gears rotate at the same speed to prevent clash when the gears are about to mesh. Whenever a vehicle is rolling, the transmission main shaft is turning and the clutch gear is spinning. Even though the clutch is disengaged, the clutch gear continues to spin until friction slows it down or stops it. Thus when the driver shifts into another gear he is trying to mesh gears that may be moving at different speeds. By using synchronizers, the possibility of broken or damaged teeth is reduced and shifting effort is lowered. [1st step] [2nd step] [3rd step]

03-22 6) Bearing The needle bearings are introduced to each gear and the taper roller bearings are used for input and counter shaft in transmission housing. Taper roller bearing Needle bearing 1.

20 ) Bearing The needle bearings are introduced to each gear and the taper roller bearings are used for input and counter shaft in transmission housing. Taper roller bearing Needle bearing 1. Taper roller bearing (input shaft, counter shaft and output shaft) 2. Needle bearings for 1/2 and 3/4 shift 3. Needle bearing for reverse gear (with cut out area) 4. Needle bearing for 5th gear 7) End Play of Taper Roller Bearing 1. Taper roller bearing for input shaft 2. Taper roller bearing for counter shaft A. End play A: 0.85 ~ 2.28 mm B. End play B: 1.17 ~ 1.97 mm Use the following spacers to adjust the end play (A or B) between input shaft and counter shaft. (Specified range of end play: 0.05 ~ 0.1 mm) - - For input shaft: 0.75 ~ 1.45 mm (15 spacers with increment of 50 μm) For output shaft: 0.4 ~ 1.45 mm (10 spacers with increment of 50 μm)

21 ) Thrust Ring (Washer) When the driving force from engine is transmitted to the output shaft of transmission, each shaft and gear assembly receives the axial force and this force acts as a resistance to rotating gears. 9) Lubrication Transmission oil: SAE 75W/90 Initial installation for taper roller bearing and needle roller bearing, lubrication for shift rail: MoS2 Grease Sealant on oil drain screw during installation: Loctite DRI LOC 200 Tightening torque: 40 ~ 50 Nm

22 WD 2WD 1. Oil filler plug 2. Air vent Sealant on oil drain screw during installation: Loctite DRI LOC 200 Tightening torque: 40 ~ 50 Nm

23 CIRCUIT DIAGRAM (BACKUP LAMP)

TSM54/52 MANUAL TRANSMISSION

3B-1 SECTION 00 3B TSM54/52 MANUAL TRANSMISSION Table of Contents GENERAL INFORMATION... 3B-3 Overview... 3B-3 Specifications... 3B-4 System components... 3B-5 Shifting mechanism... 3B-17 Diagnostic information