Removing the gearbox M5GF1 and M5GF2 Kia Magentis

Remove the gearbox to replace the clutch components and for repairs

Place the car on a lift or inspection pit

Gearbox M5GF1: 1 - retaining ring; 2 - fifth gear pinion; 3 - fourth gear pinion sleeve; 4 - bolt; 5 - fourth gear pinion; 6 - third and fourth synchronizer hubs with sleeve; 7 - third gear pinion; 8 - first and second synchronizer hubs with sleeve; 9 - first gear pinion; 10 - clutch housing; 11 - input shaft front ball bearing; 12 - input shaft; 13 - output shaft front tapered roller bearing; 14 - output shaft; 15 - differential tapered roller bearing; 16 - differential; 17 - differential pinion gear; 18 - drain plug; 19 - second gear pinion sleeve; 20 - third gear input shaft pinion; 21 - fourth gear input shaft pinion; 22 - fifth gear pinion sleeve; 23 - output shaft rear tapered roller bearing; 24 - reverse pinion pinion sleeve; 25 - fifth synchronizer hub with sleeve; 26 - input shaft rear ball bearing; 27 - reverse driven gear
M5GF2 gearbox: 1 - gearbox housing; 2 - outer rings of roller bearings; 3 - first and second shaft fork; 4 - reverse gear engagement fork; 5 - engagement fork shaft; 6 - third and fourth shaft fork; 7 - fifth and sixth shaft fork; 8 - spring-loaded pin; 9 - input shaft; 10 - oil deflector; 11 - first output shaft; 12 - second output shaft; 13 - differential assembly; 14 - needle bearing; 15 - clutch housing; 16 - clutch release clutch assembly; 17 - breather

Disconnect the battery terminals and remove it

Removing the M5GF1 and M5GF2 gearbox Kia Magentis

Removing the M5GF1 and M5GF2 gearbox Kia Magentis

Removing the engine cover

Removing the M5GF1 and M5GF2 gearboxes Kia Magentis

Disconnect the PCM connector (A) and remove the air filter (B)

Removing the gearbox M5GF1 and M5GF2 Kia Magentis

Removing the battery shelf (A)

Removing the gearbox M5GF1 and M5GF2 Kia Magentis

Disconnecting ground wire (A) from the gearbox

Removal of the M5GF1 and M5GF2 Kia Magentis gearbox

Remove the rear light switch (A) and the speedometer (B)

Removal of the M5GF1 and M5GF2 Kia Magentis gearbox

Removing the gearshift cable assembly (A)

Removing the M5GF1 and M5GF2 Kia Magentis gearbox

Removing the clutch release cylinder (A)

Drain the power steering coolant and unscrew the high-pressure power steering hose mounting bolt

Removal of the M5GF1 and M5GF2 gearbox Kia Magentis

Using the 09200-38001 tool, we fix the power unit

Removing the M5GF1 and M5GF2 Kia Magentis gearbox

Removing the power unit protection

Removing the M5GF1 and M5GF2 Kia Magentis gearbox

Unscrew the drain plug (A) and drain the oil, having first unscrewed the filler cap (B)

Drain the power steering fluid

Disconnect the electric power steering connector

Unscrew the bolts securing the lower arm ball joint assembly

Unscrew the stabilizer strut bolts

After removing the steering knuckle and the nut from the steering rod end, disconnect his

Removal of the M5GF1 and M5GF2 gearbox Kia Magentis

Disconnect the hose (A) after removing the clamp (B) of the return hose of the power steering

Removal of the M5GF1 and M5GF2 gearbox Kia Magentis

Remove the bracket (B) from the front retainer (A)

Removing the M5GF1 and M5GF2 Kia Magentis gearbox

Remove the bracket (B) from the rear retainer (A)

Unscrew the steering column bolt

Removing the M5GF1 and M5GF2 Kia Magentis gearbox

Unscrew the lower mounting bolts (A) of the gearbox

Removing the M5GF1 and M5GF2 Kia Magentis gearbox

Removing the M5GF1 and M5GF2 gearboxes Kia Magentis

After disconnecting the outlet pipe (A), remove the holder (B) and disconnect the oxygen sensor connector (C)

Removing the M5GF1 and M5GF2 Kia Magentis gearbox

Supporting the crossbar (A) with a jack, remove the pillar (C) with bolts (B)

Removing the M5GF1 and M5GF2 Kia Magentis gearbox

Disconnect the drive shafts (A) from the gearbox (B) using a special mounting blade

Supporting the box with a jack, remove the support bracket (A) and the upper mounting bolts (B)

Removing the M5GF1 and M5GF2 Kia Magentis gearbox

Gradually lower the jack and remove the gearbox

Install the gearbox in the reverse order sequences

Bolt tightening torques:

  • - support bracket 42.2- 53.9 Nm;
  • - gearbox mounting bracket 63.7~83.4 Nm;
  • - cross beam 137.3~156.9 Nm and 44.1-58.8 Nm (struts);
  • - steering column 14.7-19.6 Nm;
  • - retainer bracket 49.0-63.7 Nm;
  • - stabilizer struts 98.1-117.7 Nm;
  • - lower arm ball joint 98.1-117.7 Nm;
  • - pressure hose 63.7-73.5 Nm;
  • - drain plug 29.4-34.3 Nm;
  • - tie rod end nuts 23.5-33.3 Nm.