General Information

Specifications
1TON
Transmission type
M6AR1
Engine type Diesel 2.5
1st 4.271
2nd 2.248
3rd 1.364
Gear ratio 4th 1.000
5th 0.823
6th 0.676
Reverse 3.814
Final gear ratio 3.727

Tightening Torques
Items N.m kgf.m lb-ft
Oil drain plug 58.9 ~ 78.5 6.0 ~ 8.0 43.4 ~ 57.8
Oil filler plug 58.9 ~ 78.5 6.0 ~ 8.0 43.4 ~ 57.8
Back up lamp switch 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Control shaft assembly bolt 26.5 ~ 33.3 2.7 ~ 3.4 19.5 ~ 24.6
Neutral switch 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Speed sensor bolt 4.9 ~ 6.9 0.5 ~ 0.7 3.6 ~ 5.1
Start motor installation bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Transmission upper mounting bolt (TM=>ENG) 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8

Lubricants
Quantity
Items Recommnend lubricant
PTO (O) PTO (X)
2.6 ~ 2.7 L 2.2 ~ 2.3 L
SAE 75W/85
(0.69 ~ 0.71 U.S.gal., 2.75 (0.58 ~ 0.61 U.S.gal., 2.32
Transmission gear oil API GL-4
~ 2.85 U.S. qt., 2.29 ~ 2.38 ~ 2.43 U.S. qt., 1.94 ~ 2.02
TGO-7
lmp qt.) lmp qt.)

Sealant
Items Specified sealant
Control shaft assembly MS721-40 or MS721-38
Special Service Tools
Tool
Illustration Use
(Number and Name)
09452-25300 Installation of transmission case oil se-
Oil seal installer al.
[Using with handle (SST No.09231-H1
100)]

S92MT9041D

09231-H1100 Installation of transmission case oil se-

Bar al.
[Using with oil seal installer (SST No.:0
9452-25300)]

SLD766035D
Manual Transmission System
Manual Transmission Fluid
Components Location

SPUMT2002D

1. Oil filler plug 2. Oil drain plug

General Information
1. Check & Change intervals

Check & Reflenish - Change Capacity

Oil specification
ment Nomal Use Severe Use PTO (O) PTO (X)
60000 km / 4 years 2.6 ~ 2.7 L 2.2 ~ 2.3 L

120000 km (0.69 ~ 0.71 U.S. (0.58 ~ 0.61 U.S. SAE 75W/85, API
No service required
(40000 miles / 4years) (80000 miles) gal., 2.75 ~ 2.85 gal., 2.32 ~ 2.43 GL-4
U.S. qt., 2.29 2. U.S. qt., 1.94 ~ 2.
~
38 lmp qt.) 02 lmp qt.)

3. Check the oil level.

Severe usage is defined as

• Driving in rough road (Bumpy, Gravel, Snowy, Oil level must be up to fill the hole, if not, add oil until
Unpaved road, etc) it runs over.
• Driving in mountain road, ascent/descent
• Repetition of short distance driving.
• More than 50% operation in heavy city traffic
during hot weather above 30°C(89.6°F).
• Police, Taxi, Commercial type operation or trailer
towing, etc.

Inspection
1. Stop the engine and uplift the vehicle with lift.
2. Loosen the oil filler plug (A).

SBKMT9018D

4. Install the filler plug.

Tightening torque:
58.9 ~ 78.5 N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.8 lb-ft)

SPUMT2100D
Replacement
1. Stop the engine and uplift the vehicle with lift.
2. Drain the manual transmission oil after loosening the
drain plug (A).

SPUMT2101D

3. Install the drain plug with new gasket.

Tightening torque:
58.9 ~ 78.5 N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.9 lb-ft)
4. Add new oil through the filler plug hole and, fill it just
below the plug opening.
Quantity
Items Recommnend lubricant
PTO (O) PTO (X)
2.6 ~ 2.7 L 2.2 ~ 2.3 L
SAE 75W/85
Transmission gear oil API GL-4 (0.69 ~ 0.71 U.S.gal., 2.75 (0.58 ~ 0.61 U.S.gal., 2.32
TGO-7 ~ 2.85 U.S. qt., 2.29 ~ 2.38 ~ 2.43 U.S. qt., 1.94 ~ 2.02
lmp qt.) lmp qt.)
Manual Transmission
Components

SPUMT2001D

1. Transmission housing 5. Roll support bracket

2. CKP sensor 6. Vehicle speed sensor
3. Neutral switch 7. Back up lamp switch
4. Control shaft complete 8. Manual control lever
Removal 6. Disconnect the speed sensor connector (A) and back
up lamp switch connector(B).
7. Separate the wiring from the bracket (C).
• Use fender covers to avoid damaging painted
surfaces.
• To avoid damage, unplug the wiring connectors
carefully while holding the connector portion.

1. Remove the battery (-) terminal.

2. Remove the propeller shaft.
(Refer to Driveshaft and axle - "Propeller Shaft
Assembly")
3. Remove the side cover (A).

SPUMT2005D

8. Remove the control cable (A).

1) Remove the pin and washer.
2) Remove the cable guide (B) from the bracket.

KMSE050M

4. Remove the ground (A).

5. Disconnect the CKP sensor connector (B) and neutral
switch connector (C).

SPUMT2006D

SPUMT2004D
9. Separate the wiring (A) from the cable bracket. 11.Remove the roll support bracket bolt (A) by
supporting it with a jack.

SPUMT2007D

10.Remove the clutch release cylinder assembly (A) SHRMT2100L

after removing the bolts. 12.Remove the transmission mounting bolts.

Tightening torque : Tightening torque :
31.4 ~ 41.2 N.m (3.2 ~ 4.2 kgf.m, 23.1 ~ 30.4 lb-ft) 42.2 ~ 54.0 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

SPUMT2008D SPUMT2010D

SPUMT2011D
Installation

• If the oil seal on the transmission case side is

damaged and fluid is leaking, replace the oil seal with
a new unit. When installing the new oil seal, use the
oil seal installer (09452-25300).

1. Install in the reverse order of removal.

2. Adding manual transmission fluid after Installing the
manual transmission.
(Refer to Manual transmission System - "Manual
transmission Fluid")
Vehicle Speed Sensor
Description
Vehicle Speed Sensor (VSS) is hall sensor type and
senses the rotating speed of differential gear mounted on
transmission.
Comparing engine speed with vehicle speed calculated
based on vehicle speed sensor signal, ECM recognizes
engaged gear.
And based on the information about engaged gear, ECM
performs optimum fuel injection quantity correction.
VSS signal is also used in speed meter of cluster, A/C
control module, BCM, etc.

SPUMT2016D

Component Location

SPUMT2102D

1. Vehicle speed sensor 2. Driven gear

Specification Inspection
Item Specification 1. Check the damage to the connectors and wiring.
2. Check the power.
Type Hall sensor
1) Turn ignition switch OFF.
Working voltage 6.5 ~1 5V
2) Disconnet the vehicle speed sensor.
VL ≤ 0.5 V 3) Turn ignition switch ON.
Output voltage (When output current is 15
4) Check the voltage of the power terminal.
mA flows)
Specification : 11.5V ~ 13.0V
3. Check the signal.
1) Turn ignition switch OFF.
2) Disconnet the vehicle speed sensor.
3) Turn ignition switch ON.
4) Check the voltage of the signal terminal.
Specification : 8.0V ~ 11.5V
4. Check the ground.
1) Turn ignition switch OFF.
2) Disconnet the vehicle speed sensor.
3) Turn ignition switch ON.
4) Check the voltage between signal terminal and
body ground.
5) Check the voltage between signal terminal and
ground terminal.
Specification : 4) - 5) = Within 200mV

Component Inspection
1. IG KEY "OFF", ENGINE "OFF".
2. Disconnect the vehicle speed sensor (VSS)
connector.
3. Disconnect the VSS and Driven gear assy′.
4. Check rotating state of VSS driven gear.
5. Connect VSS connector and IG KEY "ON".
6. Rotate Driven gear with hand.
Specification : Vehicle Speed Signal generates.
Removal 3. Remove the driven gear.
1. Disconnect the vehicle speed sensor (A). Tightening torque :
4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)

SPUMT2103D

2. Remove the vehicle speed sensor. SPUMT2015D

• After removing speed sensor, be careful not to

enter dust, foreign matters, etc in speed sensor
hole.

Installation

• Check the wear of spline (A).

• When installing, do not reuse the O-ring (B).

SPUMT2014D

SGDMT2004D

1. Install in the reverse order of removal.

Neutral Switch
Description
Neutral Gear Switch is installed in M/T vehicle (ISG
system or Diesel engines) and senses driver′s intension
to shift gear.
When vehicle starts to move after standing for a while
and vehicle speed does not reach to 2Km/h, fuel quantity
mapping value at neutral gear is adopted to vehicle.
Moreover, this phenomenon is more serious when
vehicle requires high power generation such as the
situation when vehicle is on the slope.
To cope with this problem, neutral gear switch which
senses driver′s intension of starting to move is applied.
And fuel injection quantity mapping value suitable for 1st
gear is adopted immediately. SPUMT2018D

Component Location

SPUMT2104D
Specification Inspection
Item Specification 1. Disconnect the neutral position switch connector (A).

Current voltage 12V

Working voltage 10 ~ 15V
Working temperature -30℃ ~ 80℃

SPUMT2013D

2. Check the continuity between no. 1 and 2 terminals

of neutral position switch.
When the shift lever is in neutral, there should be
continuity..

LMJF100B
Replacement
1. Disconnect the neutral position switch connector (A).
2. Remove the neutral position switch.
3. Install the neutral position switch and then connect
the neutral position switch connector.
Tightening torque :
29.4 ~ 34.3 N.m (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)

SPUMT2013D
Back-up Lamp Switch
Description
Back up lamp switch is pushed by the reverse lug sliding
when select arm, and switches the back up lamp.

SPUMT2018D

Component Location

SPUMT2105D
Specification Inspection
Item Specification 1. Disconnect the back up lamp switch connector (A).

Current voltage 12V

Working voltage DC 10~15V
Operating force 3.0kg Max
Voltage drop -0.4V
-30°C ~ 100°C
Working temperature
[-30°F ~ 212°F]

SPUMT2106D

2. Check the continuity between no. 1 and 2 terminals

of backup lamp switch. When the shift lever is in
reverse, there should be continuity.

LMJF003B
Replacement
1. Disconnect the backup lamp switch connector (A).
2. Remove the backup lamp switch.
3. Install the backup lamp switch and then connect the
backup lamp switch connector.
Tightening torque :
29.4 ~ 34.3 N.m (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)

SPUMT2106D
Manual Transmission Control System
Shift Lever
Components

SPUMT2028D

1. Knob 5. Clip
2. Boots 6. Select cable
3. Floor console assembly 7. Shift cable
4. Shift lever assembly
Removal 3. Remove the shift lever assembly (A).
1. Remove the floor Interior console assembly.
(Refer to Body - " Floor Console")
2. Remove the control cable (A) from the lever
assembly.
1) Remove the cable from the lever pin.

SPUMT2108D

Installation
1. Install in the reverse order of removal.

SPUMT2019D

2) Remove the clip (B).

SPUMT2020D
Control Cable
Components

SPUMT2107D

1. Knob 5. Clip
2. Boots 6. Select cable
3. Floor console assembly 7. Shift cable
4. Shift lever assembly
Removal 3. Remove the cable guide (A) from the body after
1. Remove the floor console assembly. pushing in the direction of the arrow.
(Refer to Body - " Floor Console")
2. Remove the control cable (A) from the lever
assembly.
1) Remove the cable from the lever pin.

SPUMT2021D

4. Pull the cable to down side.

SPUMT2019D

2) Remove the clip (B).

SPUMT2100L

5. Remove the side cover (A).

SPUMT2020D

KMSE050M
6. Remove the control cable (A) from the transmission. Installation
1) Remove the pin and washer.
2) Remove the cable guide (B) from the bracket.
• When install the select cable to lever assembly, set
the shift lever lever to 3rd or 4th position.
• Install the select cable to lever assembly after adjust
the select cable.

1. Install in the reverse order of removal.

SPUMT2006D

7. Remove the cable mounting bracket bolts (A-3ea).

SPUMT2023D

SPUMT2022D
Adjustment 4. Push the adjuster (A) after install the select cable to
Select cable adjustment the lever pin.

1. Set the shift lever lever to 3rd or 4th position.

2. Pull the adjuster (A) in the direction as shown in the
illustration.

SPUMT2116D

SPUMT2114D

3. Adjust the select cable (A) by moving the adjuster (B)

in the direction as shown in the illustration.

SPUMT2115D
Control Shaft Complete
Description Removal
• Control shaft assembly is mounted on the top of the 1. Shift lever to "Neutral" position.
manual transmission. 2. Remove the transmission assembly.
• Control shaft assembly is operated by shifting the (Refer to Manual transmission System - " Manual
shift lever. transmission")
3. Remove the pin (A-2ea) and then remove the
manual control lever (B).

SPUMT2109D

SPUMT2025D

4. Remove the control shaft (A).

To remove the control shaft must be a neutral state.

SPUMT2026D
Installation
1. Install in the reverse order of removal.

• When installing, set control shaft lever to neutral

position.
• When installing, apply the sealant as shown in the
illustration.
Specified sealant : MS 721-40 or MS721-38

SPUMT2101L