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.

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