SM 13

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Reduction Gear System
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
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• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name Illustration Description

Insulation gloves Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Used when inspecting or working on the high voltage

Insulation clothes
components
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Insulation helmet
Safety glasses
Used in the following cases :

• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
All removed high voltage components are placed on an

Insulation mat
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to

Insulation sheet protect people not wearing personal protective equipment from
safety accidents.
Warning tape Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.

• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
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Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage

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• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
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Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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4. Remove the safety plug (A).
Remove the safety plug in the follwing order.

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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
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(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Specifications
Item Specifications
Reduction gear ratio 8.206
Maximum torque 285 Nm
Maximum RPM 10500 RPM
Tightening Torques
Item N.m kgf.m lb-ft
Reduction gear mounting bolt 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Reduction gear front mounting bolt 63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
Reduction gear front bracket
107.9 ~ 127.5 11.0 ~ 13.0 79.6 ~ 94.0
bolts / nut
63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
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Reduction gear rear bracket bolts /

nut
Manual control lever mounting
9.8 ~ 13.7 1.0 ~ 1.4 7.2 ~ 10.1
bolts
Inhibitor switch mounting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Shift cable bracket mounting bolt 19.6 ~ 16.5 2.0 ~ 2.7 14.5 ~ 19.5
Shift lever assembly mounting bolt 9.8 ~ 13.7 1.0 ~ 1.4 7.2 ~ 10.1
Lubricants
Item Specified lubricant Quantity
1.2 ~ 1.4 L (0.317 ~ 0.370 U.S gal., 1.27 ~
Reduction gear fluid SAE 75W/API 85,GL-4
1.48 U.S.qt., 1.06 ~ 1.23 Imp.qt.)
Special Service Tools

Tool Name / Number Illustration Description
Oil seal installer

A: 09365-E1100 (Installer) Installation of transaxle case oil seal.
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B: 09231-H1100 (Handle)
Inhibitor switch guide pin

Inhibitor neutral fixed.
0K948-E4000
Commercial Tool
Tool Name Illustration Description
Used for holding motor assembly when

Auto bar
removing / installing gear drive unit
Component
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1. Differential Oil Seal 3. Oil Drain Plug
2. Oil Filler Plug
Inspection
1. Lift the vehicle.
2. Remove the under cover.
(Refer to Traction Motor System - "under cover")
3. Remove the oil filler plug (A).
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4. Check the oil condition and then oil level (A).
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If the oil level is low, supplement the oil up to filler plug hole.
5. Install the oil filler plug (A).
Must replace with new gasket when installing the drain plug.
Replacement
Gear differential unit system does not need to be replaced for Normal Usage. If the vehicle is used for any of the Severe Usage
conditions listed below, replace the 120,000 miles. Severe usage is defined as
• Driving in rough road (Bumpy, Gravel, Snowy, Unpaved road, etc)
• Driving in mountain road, ascent/descent
• Repetition of short distance driving
• More than 50% operation in heavy city traffic during hot weather above 32°C(89.6°F) .
• Police, Taxi, Commercial type operation or trailer towing, etc
1. Using the lift raise the car.
2. Remove the under cover.
3. Remove the drain plug (A) and drain the oil totally and then reinstall the drain plug.
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Must replace with new gasket when installing the drain plug.
4. Remove the oil filler plug (A).
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5. Supplement up to oil filler plug hole.
6. Install the oil filler plug (A).
7. Install the under cover.

Description
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• The role of reduction gear is similar to transmission. But unlike the transmission which has various gear ratio, the reduction gear
transfers the motor power with fixed reduction gear ratio.
• The reduction gear increases the torque by reducing the motor speed.
• There are 5 gears inlcuding parking gear in the inner of reduction gear and the MT oil is used for reduction gear. And no need to change
the oil.
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Components Location
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1. Motor assembly 2. Reduction Gear
Components
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1. Differential Oil Seal 3. Oil Drain Plug
2. Oil Filler Plug
Removal
• Use the fender cover to prevent the damage on the painting.

• Disconnect the connector & wiring to prevent the damage.
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Shut off the high voltage.
(Refer to Reduction Gear System. - " High Voltage Shut-off Procedures")
2. Remove the auxiliary 12V battery and auxiliary 12V battery tray.
(Refer to Vehicle Control System - "Auxiliary 12V Battery")
3. Remove the power electric cover.
(Refer to Traction Motor System - "Power Electric Cover")
4. Remove the high voltage joint box.
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(Refer to EV Battery System - "High voltage joint box")

5. Remove the on-board charger (OBC).
(Refer to Battery Control System - "On-Board Charger (OBC)")
6. Remove the electric power control unit (EPCU).
(Refer to Vehicle Control System - "Electric Power Control Unit (EPCU)")
7. Disconnect the inhibitor switch connector (A).
8. Remove the shift cable (C) by loosening the bolts (A) and nut (B).
Tightening torque:
(A): 19.6 ~ 16.5 N.m ( 2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
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(B): 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
9. Remove the nut (A) and then separate the A/C pipe.
Tightening torque:
7.8 ~ 11.8 N.m ( 0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft)
10. Remove the reduction gear upper mounting bolts (A).

Tightening torque:
42.2 ~ 53.9 N.m ( 4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
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11. Remove the front mounting bracket upper mounting bolt (A).
Tightening torque:
63.7 ~ 83.4 N.m ( 6.5 ~ 8.5kgf.m, 47.0 ~ 61.5 lb-ft)
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12. Remove the electric A / C compressor.
(Refer to Heating,Ventilation And Air Conditioning - "Electric A / C Compressor")
13. Fix motor by using the auto bar (A).
14. Remove the drive shaft.

(Refer to Driveshaft and axle - "Front Driveshaft")
15. Fix reduction gear, and then remove the reduction gear lower mounting bracket mounting bolts (A) and (B) .
Tightening torque:
(A): 63.7 ~ 83.4 N.m ( 6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
(B): 42.2 ~ 53.9 N.m ( 4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
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16. Remove the reduction gear mounting bracket (C).

Tightening torque:
(A): 107.9 ~ 127.5 N.m ( 11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
(B): 63.7 ~ 83.4 N.m ( 6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
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17. Remove the reduction gear lower mounting bolts (A).
Tightening torque:
42.2 ~ 53.9 N.m ( 4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
18. Remove the reduction gear by using the jack.
Installation
1. Install in the reverse order of removal.
If oil leak happens by damage on the oil seal, replace with new oil seal.
When installing the oil seal, use the oil seal installer(09365-E1100).
2. Reduction gear oil supplement by install the reduction gear.
(Refer to Reduction Gear Assembly - "oil")
3. Fill the reservoir with coolant.
(Refer to Motor Cooling System - "Coolant")
Description
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Inhibitor Switch monitors the lever's position(P, R, N, D) and is used to control gear setting signals.
Specifications
▷ Type: Combination of output signals from 4 terminals
Power supply (V) 12
Output type Combination of output signals
Signal Code Table
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P P-R R R-N N N-D D
S1 12V 12V 0 0 0 0 0
S2 0 12V 12V 12V 0 0 0
S3 0 0 0 12V 12V 12V 0
S4 0 0 0 0 0 12V 12V
Circuit Diagram
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Inspection
Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage.
Power Circuit Inspection

1. Disconnect the Inhibitor switch connector.
2. Ignition KEY "ON"" & Engine "OFF".
3. Measure voltge between supplied power and ground at inhibitor circuit.
Specification : Approx. 12V
Signal Circuit Inspection

1. Connect the Inhibitor switch connector.
2. Ignition KEY "ON" & Engine "OFF".
3. Measure voltages between each terminal and chassis ground during shift lever changed "P, R, N, D".
Specification : See below "Signal Code Table"
Signal Code Table
P P-R R R-N N N-D D
Signal "1" 12V 12V 0 0 0 0 0
Signal "2" 0 12V 12V 12V 0 0 0
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Signal "3" 0 0 0 12V 12V 12V 0

Signal "4" 0 0 0 0 0 12V 12V
Removal

1. Place the shift lever into the "N" position.
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10. Loosen the nut (A) and then remove the manual control lever (B).
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11. Loosen the nut (B) and then remove the inhibitor switch(A).
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Installation
1. Place the shift lever into the "N" position.
2. Install the inhibitor switch (A) and then tighten the bolt (B).
Fasten the bolt loosely to adjust.
3. Install the manual control lever (B) and then tighten the nut (A)..

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4. Align the hole (A) in the manual control lever with the "N" position hole (B) of the inhibitor switch and then insert the SST inhibitor switch
guide pin (0K948-E40000).
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5. Tighten the nut (A) and the bolt 2 ea (B) with the specific torque.
Tightening torque:
(A): 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
(B): 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
6. Remove the SST (0K948-E40000).

7. Connect the inhibitor switch connector (A).
8. Install the shift cable and then tighten the nut (B).
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9. Push the shift cable adhere to the direction of the arrow and then tighten the nut.
Tightening torque:
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 7.2 ~ 10.1 lb-ft)
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10. Install the electric power control unit (EPCU).
11. Install the on-board charger (OBC).
12. Install the high voltage joint box.
13. Install the power electric cover.
14. Install the auxiliary 12V battery and auxiliary 12V battery tray.
15. Install the high voltage.
Components
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1. Shifter lever assembly 4. Key inter lock switch
2. Shift cable retainer 5. Manual mode switch housing
3. Shift cable assembly 6. Shift lock solenoid
Removal
1. Remove the shift lever knob & boots assembly (A) by Pulling in the upside.
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2. Remove the floor console assembly.

(Refer to Body - "Floor Console Assembly ")
3. Disconnect the shift lever switch connector (A).
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4. Remove the wiring fastener (A) from the shift lever assembly.
5. Seperate the lever pin (B) and then remove the shift cable (A).
6. Remove the shift lever assembly (B) by loosening the bolts (A).
Tightening torque:
1.0 ~ 1.4 kgf.m
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When installing, set room side shift lever and T/M side lever to "N" position.
Replacement
Shift lock solenoid replacement
1. Remove the plastic bracket (B) by loosening the screw (A).
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2. Remove the shift lock solenoid (A) from the shift lever assembly.
3. Disconnect the key inter lock switch (B) by removeing the plastic bracket (A).
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4. Disconnect the shift lever main connector (A).
5. Remove the wiring fixed bracket in the main connector.
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6. Remove the shift lock solenoid wiring from the main connector
Be sure to check the wiring color before disconnecting the wiring.
Pin Function
3 Shift lock solenoid (-)
4 Shift lock solenoid (+)
9 Key inter lock switch (-)
10 Key inter lock switch (+)
Key inter lock switch

1. Remove the plastic bracket (B) by loosening the screw (A).
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2. Remove the shift lock solenoid (A) from the shift lever assembly.
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3. Disconnect the key inter lock switch (B) by removing the plastic bracket (A).
4. Disconnect the shift lever main connector (A).
5. Remove the wiring fixed bracket in the main connector.

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6. Remove the shift lock solenoid wiring from the main connector
Be sure to check the wiring color before disconnecting the wiring.
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Pin Function
3 Shift lock solenoid (-)
4 Shift lock solenoid (+)
9 Key inter lock switch (-)
10 Key inter lock switch (+)
Components
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1. Shifter lever assembly 4. key inter lock switch
2. Shift cable retainer 5. Manual mode switch housing
3. Shift cable assembly 6. Shift lock solenoid
Removal

1. Remove the shift lever knob & boots assembly (A) by Pulling in the upside.
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2. Remove the floor console assembly.

(Refer to Body - "Floor Console Assembly ")
3. Seperate the lever pin (B) and then remove the shift cable (A).
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4. Remove the retainer (A) by loosening the nuts (B).
Tightening torque:
9.8 ~ 13.7 N.m ( 1.0 ~ 1.4 kgf.m, 7.2 ~ 10.1 lb-ft)

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Tightening torque:
(A): 19.6 ~ 16.5 N.m ( 2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
(B): 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
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13. Remove the shift cable by pulling it toward the interior.
Installation
Install the cable after placing the shift lever and the transaxle manual control lever in the N position.

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Page 1 sur 34

Reduction Gear System

• All the high voltage wiring and connectors are in orange.

Name Illustration Description

Used when inspecting or working on the high voltage

Used in the following cases :

All removed high voltage components are placed on an

Insulation sheet is used to cover high voltage components to

Personal Protective Equipment Inspection

• Check that the personal protective equipment is not damaged.

Precautions when handling high voltage battery

• Battery Control System - Refer to "High Voltage Battery Handling Guide"

Precautions in case of fire in High Voltage Battery System

Precautions in case of high voltage battery gas and/or electrolyte leakage

Precautions when handling vehicle after an accident

Precautions when EV is unattended for a prolonged period

Hybrid Vehicle Refrigerant Recovery / Charging Precautions

Reduction Gear System

High Voltage Shut-off Procedure

Remove the safety plug in the follwing order.

(3) Remove the high voltage cable (A).

Reduction gear rear bracket bolts /

Reduction Gear System

Special Service Tools

Oil seal installer

Inhibitor switch guide pin

Used for holding motor assembly when

Reduction Gear System

Reduction Gear System

4. Check the oil condition and then oil level (A).

6. Install the oil filler plug (A).

7. Install the under cover.

Reduction Gear System

• Use the fender cover to prevent the damage on the painting.

(Refer to EV Battery System - "High voltage joint box")

10. Remove the reduction gear upper mounting bolts (A).

14. Remove the drive shaft.

16. Remove the reduction gear mounting bracket (C).

18. Remove the reduction gear by using the jack.

Reduction Gear System

Signal Code Table

Reduction Gear System

Power Circuit Inspection

Signal Circuit Inspection

Signal "3" 0 0 0 12V 12V 12V 0

• Use the fender cover to prevent the damage on the painting.

Fasten the bolt loosely to adjust.

Fasten the bolt loosely to adjust.

6. Remove the SST (0K948-E40000).

Fasten the bolt loosely to adjust.

Reduction Gear System

2. Remove the floor console assembly.

7. Install in the reverse order of removal.

4. Disconnect the shift lever main connector (A).

5. Remove the wiring fixed bracket in the main connector.

Be sure to check the wiring color before disconnecting the wiring.

Key inter lock switch

4. Disconnect the shift lever main connector (A).

5. Remove the wiring fixed bracket in the main connector.

Be sure to check the wiring color before disconnecting the wiring.

Reduction Gear System

Reduction Gear System