mtmanual transmission 3170-01 -...

03-3

MANUAL TRANSMISSIONREXTON 2004.04

3170-01

3170-01MTMANUAL TRANSMISSION

1. SPECIFICATIONS1) General Specifications

2) Tightening Torque

GENERAL

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REXTON 2004.04

3170-01

MANUAL TRANSMISSION

OVERVIEW AND OPERATION PROCESS1. OVERVIEW

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.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.

1.

2.

4WD

2WD (Gasoline)

▶Features

All gears use the helical type and high strength materials.

1.

The helical type gear prevents the axial gear missing and provides less noise.

The synchronizing devices are installed in 1/2, 3/4, 5/R gears. To prevent the double engagement, the independent interlock devices are installed.

2.

TSM54/52 transmission uses the inertia lock type key to make smooth gear engagement and to provide silent gear engagement.

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.The semi-remote control type gear shift mechanism is used to prevent incorrect shifting.

3.

4.

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2. SYSTEM COMPONENTS1) Gear Combinations

2) Shift Fork and Rail Combinations

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MANUAL TRANSMISSION

3) Sectional View

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1. Transmission front housing2. Input shaft oil seal3. Front cover4. Hexagon flange bolt (17 ~ 26 Nm)5. Oil drain plug6. Sealing7. Pin8. Input shaft9. Clutch 4th gear10. Taper roller bearing (main)11. Taper roller bearing12. Counter shaft13. Taper roller bearing (counter)14. Output shaft15. Inner race (reverse)16. Inner race (1st)17. Needle bearing18. 1st gear19. 1st clutch gear20. Synchro outer ring21. Synchro - middle cone22. Synchro inner ring23. Synchro spring24. Synchro key25. Synchro hub26. Double synchro sleeve27. 2nd gear28. 3rd gear29. 3rd clutch gear30. Synchro hub (3 & 4th)31. Synchro ring (4/5/R)32. Single synchro sleeve33. Retainer ring34. Adaptor dowel pin35. Reverse idler shaft36. Dowel pin37. Needle bearing

38. Reverse idler gear39. Reverse idler spacer40. Reverse idler bracket41. Retainer ring42. Reverse lock nut43. Transmission adaptor44. Input shaft spacer45. Counter spacer46. Reverse needle bearing47. Reverse gear48. Reverse clutch gear49. Reverse counter gear50. Synchro hub51. Counter 5th gear52. 5th needle bearing53. 5th gear54. 5th clutch gear55. Thrust washer56. Spring pin57. 5th outside retainer ring58. 5th retainer ring59. Counter shaft bushing60. Counter roller bearing assembly61. Retainer ring62. Extension housing63. Output shaft oil seal64. Offset plate65. Counter screw66. Top cover67. Counter oil seal68. Shift shaft69. Shift lever70. Detent pin71. Joint pin72. Retainer ring73. Semi remote lever assembly

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REXTON 2004.04

3170-01

MANUAL TRANSMISSION

▶IDI Engine equipped vehicle - 4WD

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3170-01

1. Transmission front housing2. Input shaft oil seal3. Front cover4. Hexagon flange bolt (17~26 Nm)5. Oil drain plug6. Sealing7. Pin8. Input shaft9. Clutch 4th gear10. Taper roller bearing (main)11. Taper roller bearing12. Counter shaft13. Taper roller bearing (counter)14. Output shaft15. Inner race (reverse)16. Inner race (1st)17. Needle bearing18. 1st gear19. 1st clutch gear20. Synchro outer ring21. Synchro - middle cone22. Synchro inner ring23. Synchro spring24. Synchro key25. Synchro hub26. Double synchro sleeve27. 2nd gear28. 3rd gear29. 3rd clutch gear30. Synchro hub (3 & 4th)31. Synchro ring (4/5/R)32. Single synchro sleeve33. Retainer ring34. Adaptor dowel pin35. Reverse idler shaft36. Dowel pin37. Bearing

38. Reverse idler gear39. Reverse idler spacer40. Reverse idler bracket41. Retainer ring42. Reverse lock nut43. Transmission adaptor44. Input shaft spacer45. Counter spacer46. Reverse needle bearing47. Reverse gear48. Reverse clutch gear49. Reverse counter gear50. Synchro hub51. Counter 5th gear52. 5th needle bearing53. 5th gear54. 5th clutch gear55. Thrust washer56. Spring pin57. 5th outside retainer ring58. 5th retainer ring59. Counter shaft bushing60. Counter roller bearing assembly61. Retainer ring62. Extension housing63. Output shaft oil seal64. Offset plate65. Counter screw66. Top cover67. Counter oil seal68. Shift shaft69. Shift lever70. Detent pin71. Joint pin72. Retainer ring73. Semi remote lever assembly74. Rear flange

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REXTON 2004.04

3170-01

MANUAL TRANSMISSION

▶IDI Engine equipped vehicle - 2WD

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3170-01

1. Transmission front housing2. Input shaft oil seal3. Front cover4. Hexagon flange bolt (17 ~ 26 Nm)5. Oil drain plug6. Sealing7. Pin8. Input shaft9. Clutch 4th gear10. Taper roller bearing (main)11. Taper roller bearing12. Counter shaft13. Taper roller bearing (counter)14. Output shaft15. Inner race (reverse)16. Inner race (1st)17. Needle bearing18. 1st gear19. 1st clutch gear20. Synchro outer ring21. Synchro - middle cone22. Synchro inner ring23. Synchro spring24. Synchro key25. Synchro hub26. Double synchro sleeve27. 2nd gear28. 3rd gear29. 3rd clutch gear30. Synchro hub (3 & 4th)31. Synchro ring (4/5/R)32. Single synchro sleeve33. Retainer ring34. Adaptor dowel pin35. Reverse idler shaft36. Dowel pin37. Bearing38. Reverse idler gear

39. Reverse idler spacer40. Reverse idler bracket41. Retainer ring42. Reverse lock nut43. Transmission adaptor44. Input shaft spacer45. Counter spacer46. Reverse needle bearing47. Reverse gear48. Reverse clutch gear49. Reverse counter gear50. Synchro hub51. Counter 5th gear52. 5th needle bearing53. 5th gear54. 5th clutch gear55. Thrust washer56. Spring pin57. 5th outside retainer ring58. 5th retainer ring59. Counter shaft bushing60. Counter roller bearing assembly61. Retainer ring62. Extension housing63. Output shaft oil seal64. Offset plate65. Counter screw66. Top cover67. Counter oil seal68. Shift shaft69. Shift lever70. Detent pin71. Joint pin72. Retainer ring73. Semi remote lever assembly74. Rear flange75. Ball bearing76. Lock nut

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MANUAL TRANSMISSION

4) Front View and Rear ViewFront view

Rear view

Oil filler plug(tightening torque: 40 ~ 50 Nm)Shift rug (3 & 4th)Spring pin (6 x 25)Shift rug (5 & reverse)Shift rail (5 & reverse)Backup lamp switch(tightening torque: 30 ~ 40 Nm)Shift rail (3 & 4th)Interlock bolt(tightening torque: 40 ~ 50 Nm)

1.

2.3.4.5.6.

7.8.

9. Shift lever10. Interlock plate11. Shift rail (1 & 2nd)12. Shift rug (1& 2nd)13. Shift fork (3 & 4th)14. Input shaft15. Counter shaft16. Reverse idler assembly17. Spring pin (6 x 25)18. Spring pin (6 x 25)

Backup lamp switchConcentric slave cylinder adaptor

Apply Loctite 243Apply Loctite DRI LOC 200

19.20.

(8)(6)

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5) Cross Sectional Diagram of Major Components

Shift rail and 5/R gear

Offset lever

Reverse lock springReverse lock plateReverse lock boltStopper plateAir vent(tightening torque: 30 ~ 40 Nm)Lock washerTGS bushingOuter spring pinTGS pinLock bolt(tightening torque: 17 ~ 26 Nm)

1.2.3.4.5.

6.7.8.9.

10.

Offset leverOffset lever bushingRolling plungerReturn springSpring plug(tightening torque: 30 ~ 35 Nm)

Apply Long-term grease MoS2when installing the offset lever.

11.12.13.14.15.

A.

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6) Power Flows

1st gearCounter shaft

2nd gear

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7) Power Flows (Cont'd)

3rd gear

4th gear

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MANUAL TRANSMISSION

8) Power Flows (Cont'd)

5th gear

Reverse gear

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3. SHIFTING MECHANISM1) Interlock SystemInterlock system prevents the gears from meshing over two sets.

2) Reverse Interlock SystemReverse interlock system prevents the gear from shifting to reverse driving position while driving forward.

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MANUAL TRANSMISSION

3) Offset Lever and Rolling PlungerTo 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 lever2. Shift lever

3. Shift shaft4. Rolling plunger (rolling plunger return spring and ball)

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3170-01

Shift check deviceIt determines the shift fork position (N or each gear) and gives a detent movementto notice a shift lever seating when operating the shift lever.Also, it prevent the selected gear from getting out of its meshed position.

1.

Gear pump out locking deviceIt prevents the shift lever is beyond the correct shift position while shifting.

2.

Guiding a control direction and preventing an over stroke

3.

4) Backup Lamp SwitchIt is normal open type switch. Its circuit is formed when the reverse gear is selected.

Sealant: Loctite DRI LOC 200Tightening torque: 3 kg.m ~ 4 kg.m

--

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MANUAL TRANSMISSION

5) 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).

3/4 and 5/R shift: Single cone type1/2 shift: Double cone type - Improving the capacity to bigger engine torque of 1/2 shift (added synchronizer inner cone and middle cone)

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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 sleeve2. Synchronizer hub3. Synchronizer ring4. Synchronizer key

5. Synchronizer key locking ring6. Synchronizer inner cone7. 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).

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▶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. Eventhough 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]

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REXTON 2004.04

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MANUAL TRANSMISSION

6) BearingThe 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(input shaft, counter shaft and output shaft)Needle bearings for 1/2 and 3/4 shift

1.

2.

Needle bearing for reverse gear(with cut out area)Needle bearing for 5th gear

3.

4.

7) End Play of Taper Roller Bearing

1. Taper roller bearing for input shaft2. Taper roller bearing for counter shaft

A. End play A: 0.85 ~ 2.28 mmB. 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)

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Needle bearingTaper roller bearing

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8) 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) LubricationTransmission oil: SAE 75W/90Initial 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 200Tightening torque: 40 ~ 50 Nm

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REXTON 2004.04

3170-01

MANUAL TRANSMISSION

1. Oil filler plug 2. Air vent

Sealant on oil drain screw during installation: Loctite DRI LOC 200Tightening torque: 40 ~ 50 Nm

4WD 2WD

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3170-01

4. CIRCUIT DIAGRAM (BACKUP LAMP)

mtmanual transmission 3170-01 -...

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