2005 Kia Sportage EX

2005-06 TRANSMISSION General - M/T - Sportage

2005-06 TRANSMISSION

General - M/T - Sportage

SPECIFICATION
SPECIFICATION
Item M5GF1
TYPE Forward 5 speed Reverse 1 speed
ENGINE 2.0L GSL
1st 3.636
2nd 2.056
3rd 1.333
Gear ratio
4th 1.061
5th 0.821
Reverse 3.455
Final Reduction Gear Ratio 4.533

SERVICE STANDARD

SERVICE STANDARD
Standard value
Differential side bearing end play
Gear backlash in differential
Input front bearing snap ring end play
Input rear bearing snap ring end play
Output front bearing snap ring end play
Output rear bearing snap ring end play
5TH input gear snap ring end play
3RD output gear snap ring end play
mm (in)
0.05T-0.10T (0.0019T-0.0039T)
0.025L-0.150L (0.00095L-0.0057L)
0.01 L-0.12L(0.00038L-0.0045L)
0.01 L-0.12L(0.00038L-0.0045L)
0.01 L-0.12L(0.00038L-0.0045L)
0.01 L-0.09L(0.00038L-0.00342L)
0.01 L-0.05L(0.00038L-0.0019L)
0.01 L-0.05L(0.00038L-0.0019L)

TIGHTENING TORQUE

TIGHTENING TORQUE
Item Nm kgf.cm lb-ft
Select lever knob 4.5~7.5 45~75 3.3~5.4
Console upper cover 9~14 90~140 6.4~10.1
Facia bracket mounting 9~14 90~140 6.5~10.1
Facia bracket mounting 2 7~11 70~110 5.1~7.9
Shift cable 8~12 80~120 5.7~8.7
Transaxle support bracket 60~80 600~800 43.4~57.9
Input speed sensor 10~12 100~120 7.2~8.7
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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Output speed sensor 10~12 100~120 7.2~8.7

Shift lever switch 10~12 100~120 7.2~8.7
Shift arm 20~27 200~270 14.5~19.6
Select lever 20~27 200~270 14.5~19.6
Reamer bolt 43~55 430~550 31.1~39.8
Side cover bolt 10~12 100~120 7.2~8.7
Release bearing sleeve mounting 6~8 60~80 4.3~5.8
Differential drive gear bolt(4WD) 130~140 1300~1400 94.1~101.2
Differential drive gear bolt(LSD) 130~140 1300~1400 94.1~101.2
Release fork shaft lever mounting 27~40 270~400 19.5~28.9
Transmission hanger mounting 15~22 150~220 10.8~15.9
Cylinder & hose assy 15~22 150~220 10.8~15.9
1st gear switch 13 130 9.4
Back-up lamp switch 30~35 300~350 21.7~25.3
Transmission stud mounting 15~20 150~200 10.8~14.5
Oil drain plug 30~35 300~350 21.7~25.3
Filler plug 35~45 350~450 25.3~32.5

LUBRICANTS

LUBRICANTS
Item Lubricant Quantity
Transmission Oil HYUNDAI GENUINE PARTS MTF SAE 2.1 L (2.2US qt, 1.8Imp
75W/85(API-GL4) qt)
Transaxle input shaft spline CASMOLY-L9508 as required
Clutch release fork shaft CASMOLY-L9508
1g
bushing
Rear axle oil SAE 80W/90(API-GL5)-SHELL SPIRAX OR 0.75l (0.79 US gt, 0.66
equivalent Imp qt)
Transfer case SAE 80W/90(API-GL5)-SHELL SPIRAX OR 0.8l (0.85 US qt, 0.7 Imp
equivalent qt)

SPECIAL TOOLS
SPECIAL TOOLS SPECIFICATION
TOOL (number and name) Illustration Use
09431 - 39000 Fig. 1 Installation of differential oil seal
Oil seal installer Use with (09500 - 11000)
09200 - 38001 Fig. 2 Removal and installation of transaxle.
Engine support fixture
09432 - 33200 Fig. 3 z Removal of 4WD coupling flange oil seal
Bearing removing plate
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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

z Removal of input shaft's gear and ball bearing

09478 - 26000 Fig. 4 Installation of 4WD coupling flange oil seal
Flange oil seal installer
09478-26100 Fig. 5 Removal of 4WD coupling back plate
Back plate remover
09433 - 21300 Fig. 6 Removal of input/Output shaft roller bearing
Bearing removing plate
09432-22000 Fig. 7 Installation of output shaft's gear and sleeve
Bearing installer
09495-33100 Fig. 8 Installation of input shaft bearing
Bearing installer
09455-21100 Fig. 9 Installation of differential ball bearing
Bearing installer
09432-H1000 Fig. 10 Removal of input/Output shaft bearing
Bearing installer
09455-32200/0K011 190 008 Fig. 11 Removal of differential bearing spacer
Oil seal puller
09495-33000 Fig. 12 Removal of ball bearing and gear
Bearing and gear puller
09433-21000 Fig. 13 Removal of differential ball bearing
Removal plate

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 1: Identifying Oil Seal Installer Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 2: Identifying Engine Support Fixture Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 3: Identifying Bearing Removing Plate Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 4: Identifying Flange Oil Seal Installer Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 5: Identifying Back Plate Remover Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 6: Identifying Bearing Removing Plate Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

Helpmelearn
October-09-08 8:54:31 PM Page 9 © 2005 Mitchell Repair Information Company, LLC.
 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 7: Identifying Bearing Installer Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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October-09-08 8:54:31 PM Page 10 © 2005 Mitchell Repair Information Company, LLC.
 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 8: Identifying Bearing Installer Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 9: Identifying Bearing Installer Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 10: Identifying Oil Seal Puller Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 11: Identifying Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 12: Identifying Bearing And Gear Puller Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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 2005 Kia Sportage EX
2005-06 TRANSMISSION General - M/T - Sportage

Fig. 13: Identifying Removal Plate Special Tool

Courtesy of KIA MOTORS AMERICA, INC.

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October-09-08 8:54:31 PM Page 16 © 2005 Mitchell Repair Information Company, LLC.