A five-speed manual gearbox mod. M5CF1.

The mechanical gearbox is made according to a two-shaft scheme with synchronized gears.

The gearbox and final drive with differential share a common crankcase.

Manual transmission details:

1 - gear change mechanism; 2, 24 - glands; 3 - gearbox housing; 4 - shift fork V gear; 5 - pin; 6 - shift rod V gear and reverse; 7 - reverse gear shift lever; 8 - shift rod III and IV gears; 9 - shift fork III and IV gears; 10 - shift rod I and II gears; 11 - shift fork of I and II gears; 12 - input shaft oil guide; 13 - sealing ring; 14 - input shaft assembly; 15 - bearing cap; 16 - remote ring; 17.19 - outer races of bearings of the secondary shaft; 18 - intermediate shaft; 20 - output shaft oil guide; 21 - oil guide; 22 - differential; 23 - clutch housing

The clutch housing is attached to the front of the gearbox housing.

A stamped steel cover is mounted on the rear of the gearbox housing.

The control drive of a manual transmission consists of a gear lever link with a ball bearing mounted on the base of the body, two cables, gear shifting and selection, as well as a mechanism installed in the gearbox housing.

Manual transmission control drive: 1 - gear lever; 2 - linkage of the gear lever; 3-shift cable; 4 - gear selection cable; 5 - levers of the gear shift mechanism; 6 - manual transmission

In order to ensure precise gear shifting, the shift lever of the shift mechanism is one-piece with a massive counterweight.

Mechanism for shifting gears of a manual transmission: 1 - gear selection cable; 2 - gear selection lever; 3 - reverse light switch; 4 - shift cable; 5 - gear lever; 6 - shift lever counterweight

The shift and select cables are structurally different from each other and are not interchangeable.

The main gear is made in the form of a pair of cylindrical gears matched according to noise.

Torque is transmitted from the driven gear of the final drive to the differential and then to the front wheel drives.

Bevel differential, four satellites.

The tightness of the connection of the internal hinges of the front wheel drives with the differential gears is ensured by oil seals.

Checking the level and topping up the oil in the gearbox

Periodically, but at least once every 15,000 km, check the oil level in the manual transmission.

The design of the manual transmission does not provide for oil changes during the entire life of the vehicle.

However, sometimes the need to change the oil may arise, for example, when switching to an oil of a different viscosity, when repairing a gearbox, etc.

It is recommended to drain the oil within 15 minutes after the trip, until it has cooled down and has good fluidity.

In a manual transmission, fill with API GL4 SAE 75W-85 oil.

You will need: socket head or key "17", syringe.

Hyundai Solaris gearbox design feature

The filler plug is located at the front of the gearbox

Hyundai Solaris gearbox design feature

Unscrew the control hole plug

The oil level should be at the edge of the control hole or be slightly lower (you can reach the surface of the oil with your finger or a screwdriver).

If the oil level is very low (cannot be checked with a screwdriver or finger), you need to add oil.

Hyundai Solaris gearbox design feature

Unscrew the filler plug

Hyundai Solaris gearbox design feature

Pour oil into the hole with a syringe or blower until it appears from the control hole

Hyundai Solaris gearbox design feature

To change the oil in the gearbox, we clean it of dirt and unscrew the drain plug

Hyundai Solaris gearbox design feature

Drain the oil into a prepared container

Hyundai Solaris gearbox design feature

The plug is sealed with a washer

Hyundai Solaris gearbox design feature

If the washer is severely crimped, it must be replaced

Screw the cork

Pour oil into the gearbox as described above.

Possible malfunctions and ways to eliminate the checkpoint

Cause of malfunction Remedy

Vibration, noise in the gearbox

Loose or damaged powertrain suspension mounts - Tighten or replace mounts

Worn or damaged gears and bearings - Repair gearbox

Wrong brand of oil filled - Fill with correct brand of oil

Engine idle adjustment error - Adjust engine idle

Insufficient oil level - Add oil to the correct level

Oil leak

Destruction, damage to oil seals or o-rings - Replace oil seals or o-rings

Difficult shifting and grinding noise when shifting

Incomplete clutch disengagement - Bleed the clutch

Faulty shift cables - Replace shift cables

Loose synchronizer springs - Repair gearbox

Wrong brand of oil filled - Change gearbox oil

Spontaneous disengagement

Worn shift forks or broken detent springs - Repair gearbox

Increased clearance of the synchronizer clutch on the hub - Repair the gearbox