Hyundai Sonata: Manual Transaxle. Repair procedures - Manual Transaxle System - Manual Transaxle SystemHyundai Sonata: Manual Transaxle. Repair procedures

Removal

1.
Remove the air duct(A).
2.
Remove the engine cover(B).
3.
Remove the air cleaner assembly(C).
4.
Remove the battery and battery tray(D).
5.
Disconnect the speed sensor connector (A).
6.
Disconnect the back up lamp switch connector (B).
7.
Remove the ground (A).
8.
Disconnect the cable assemblies (A) after removing the clips (B) and pins (C).
9.
Disconnect the concentric slave cylinder tube(B) arter removing the pins(A).
10.
Using the special tool (A)(09200-38001), support the engine transaxle assembly safely.
11.
Remove the transaxle upper mounting bolts (B-2ea) and the starter motor mounting bolts (A-2ea).
Tightening torque :
42.2~53.9N.m(4.3~5.5kgf.m, 31.1~39.8lb-ft)

12.
Remove the ECM. (Refer to "Engine Control system" in FL group.)
13.
Remove the support mounting bolt (A).
14.
Remove the automatic transaxle support bracket mounting bolt (A).
Tightening torque :
88.3~107.9N.m(9.0~11.0 kgf.m, 65.1~79.6lb-ft)

15.
Remove the mounting bracket(A).
Tightening torque :
58.8~78.5N.m(6.0~8.0kgf.m, 43.4~57.9lb-ft)

16.
Remove the under shield cover(A).
17.
Drain the manual transaxle fluid after removing the transaxle drain plug(A).
It can be easier when the oil filler plug(B) is removed.
Tightening torque :
(A) 58.5~78.5N.m (6.0~8.0kgf.m, 43.4~57.9lb-ft)
(B) 29.4~34.3N.m (3.0~3.5kgf.m, 21.7~25.3lb-ft)

18.
Remove the Sub frame assembly. (Refer to "Front suspension system" in SS group.)
19.
Remove the drive shaft assembly. (Refer to "Drive shaft assembly " in DS group.)
20.
Remove the cover(A).
21.
Remove the side cover(A).
22.
Remove the mounting bolts(A-4ea, B-2ea) of lower part of the transaxle, and the left side cover and remove the transaxle assembly by supporting it with a jack.
Tightening torque :
(A) 42.2~48.1N.m (4.3~4.9kgf.m, 31.1~35.4lb-ft)
(B) 42.2~53.9N.m (4.3~5.5kgf.m, 31.1~39.8lb-ft)
Be careful not to damage other system or parts near by when removing the engine and transaxle assembly.


Installation

1.
Installation is the reverse of removal.
2.
After completing the installation perform the following procedure;
A.
Adjust the shift cable.
B.
Refill the all fluids.
C.
Clean the battery posts and cable terminals with sandpaper and grease them to prevent corrosion before installing.

    Manual Transaxle. Components and Components Location
    Components 1. Transaxle case 2. Taper roller bearing outer race 3. 1st/2nd shift fork 4. Reverse shift fork 5. Shift rail 6. 3rd/4th shift fork 7. 5th/6th ...

    See also:

    Power outlet
    The power outlet is designed to provide power for mobile telephones or other devices designed to operate with vehicle electrical systems. The devices should draw less than 10 amps with the engin ...

    Crankshaft Position Sensor (CKPS). Description and Operation
    Description Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of the most important sensors of the If there is no CKPS signal input, the engine may stop because of ...

    Impact sensing door unlock system (if equipped)
    All doors will be automatically unlocked when the impact is delivered to impact sensors while the ignition switch is ON. However, the doors may not be unlocked if mechanical problems occur with th ...