Hyundai Cars 2006-2008

Transaxle Removal & Installation

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Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses for reassembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Record the radio anti-theft code data.
  4.  
  5. Disconnect the negative terminal from the battery, then disconnect the positive terminal from the battery.
  6.  
  7. Remove the battery.
  8.  
  9. Disconnect the AFS connector.
  10.  
  11. Remove the air cleaner upper cover (B) by loosening the clips (A).

    Click image to see an enlarged view

    Fig. Remove the air cleaner upper cover (B) by loosening the clips (A)

  12.  
  13. Remove the air cleaner assembly.
  14.  
  15. Disconnect the air cleaner hose by loosening the clamp.
  16.  
  17. Remove the battery tray by removing the 4 mounting bolts.
  18.  
  19. Disconnect the transaxle wire harness connectors:
    1. Remove the inhibiter switch connector.
    2.  
    3. Remove the solenoid valve connector.
    4.  
    5. Remove the input speed sensor connector.
    6.  
    7. Remove the output speed sensor connector.
    8.  
    9. Remove the vehicle speed sensor connector.
    10.  
    11. Remove the CKP sensor connector.
    12.  

  20.  
  21. Remove the ground circuit line from the transaxle.
  22.  
  23. Remove the shift cable by removing the bolt (A) and clip (B).

    Click image to see an enlarged view

    Fig. Remove the shift cable by removing the bolt (A) and clip (B)

  24.  
  25. Disconnect the transaxle oil cooler hoses (A) from the tubes (C) by loosening the clamps (B).

    Click image to see an enlarged view

    Fig. Disconnect the transaxle oil cooler hoses (A) from the tubes (C) by loosening the clamps (B)

  26.  
  27. Remove the transaxle mounting bolts (B, C).

    Click image to see an enlarged view

    Fig. Remove the transaxle mounting bolts (B, C)

  28.  
  29. Using the SST(09200-38001), hold the engine and transaxle assembly safely.

    Click image to see an enlarged view

    Fig. Using the SST(09200-38001), hold the engine and transaxle assembly

  30.  
  31. Remove the transaxle insulator mounting bolt (A).

    Click image to see an enlarged view

    Fig. Remove the transaxle insulator mounting bolt (A)

  32.  
  33. Remove the front wheels.
  34.  
  35. Remove the power steering column joint bolt.
  36.  
  37. Raise and safely support the vehicle.
  38.  
  39. Remove the undercover.
  40.  
  41. Drain transaxle oil.
  42.  
  43. Drain the power steering oil through the return tube.
  44.  
  45. Disconnect the power steering pressure tube from the power steering oil pump.
  46.  
  47. Disconnect the lower arm, the tie rod end ball joint, and the stabilizer bar control link from the front knuckle.
  48.  
  49. Remove the roll stopper mounting bolts (A) and (B).

    Click image to see an enlarged view

    Fig. Remove the roll stopper mounting bolt (A)



    Click image to see an enlarged view

    Fig. Remove the roll stopper mounting bolt (B)

  50.  
  51. Remove the mounting bolts from the sub frame by supporting the sub frame with a jack.
  52.  
  53. Remove halfshafts from the transaxle. Refer to Halfshafts, removal & installation.
  54.  
  55. Install a jack for supporting the transaxle assembly.
  56.  
  57. Remove the transaxle under mounting bolts (A) and the drive plate bolts (B).
  58.  
  59. Lifting the vehicle up and lowering the jack slowly, remove the transaxle assembly.

    Click image to see an enlarged view

    Fig. Remove the transaxle under mounting bolts (A) and the drive plate bolts (B)

  60.  

To install:

  1. Lower the vehicle or lift up the jack to install the transaxle assembly.
  2.  
  3. Tighten the transaxle under mounting bolts to: 47-62 ft. lbs. (65-85 Nm).
  4.  
  5. Install the starter motor, if removed. Tighten the bolts to: 47-62 ft. lbs. (65-85 Nm).
  6.  
  7. Tighten the transaxle under mounting bolts to: 33-38 ft. lbs. (46-53 Nm).
  8.  
  9. After removing the jack, install the halfshafts. Refer to Halfshafts, removal & installation.
  10.  
  11. Install the sub frame.
  12.  
  13. Tighten the roll stopper mounting bolts. Tighten to: 65-80 ft. lbs. (90-110 Nm).
  14.  
  15. Connect the return tube with a clamp.
  16.  
  17. Connect the lower arm, the tie rod end ball joint, and the stabilizer bar control link to the front knuckle.
  18.  
  19. Connect the power steering pressure tube to the power steering oil pump.
  20.  
  21. Install the undercover.
  22.  
  23. Install the steering column joint bolt.
  24.  
  25. Install the front wheels and tires.
  26.  
  27. Tighten the transaxle insulator mounting bolt to: 65-80 ft. lbs. (90-110 Nm).
  28.  
  29. Tighten the transaxle mounting bolts to: 47-62 ft. lbs. (65-85 Nm)
  30.  
  31. Remove the SST (09200-38001) holding the engine and transaxle assembly.
  32.  
  33. Connect the transaxle oil cooler hoses to the tubes by fastening the clamps.
  34.  
  35. Install the shift cable by tightening the bolt and clip. Tighten the bolt to: 84-120 inch lbs. (10-14 Nm).
  36.  
  37. Connect the transaxle wire harness connectors:
    1. Install the inhibiter switch connector.
    2.  
    3. Install the solenoid valve connector.
    4.  
    5. Install the input speed sensor connector.
    6.  
    7. Install the output speed sensor connector.
    8.  
    9. Install the vehicle speed sensor connector.
    10.  
    11. Install the CKP sensor connector.
    12.  

  38.  
  39. Install the ground circuit line to the transaxle.
  40.  
  41. Install the battery tray by tightening the 4 mounting bolts.
  42.  
  43. Connect the air cleaner hose by fastening the clamp.
  44.  
  45. Install the air cleaner assembly.
  46.  
  47. Install the air cleaner upper cover by fastening the clips.
  48.  
  49. Connect the AFS connector.
  50.  
  51. Install the battery.
  52.  
  53. Refill the power steering fluid and bleed the power steering system.
  54.  
  55. Fill the transaxle with the proper grade and type of transaxle fluid.
  56.  
  57. Run the engine and recheck the transaxle fluid. Road test the vehicle.
  58.  
  59. Reprogram the radio anti-theft codes.
  60.  
  61. When replacing the automatic transaxle, reset the automatic transaxle values by using the High-Scan Pro tool:
    1. Connect the Hi-Scan Pro connector to the Data Link Connector (DLC) under the crash pad and the power cable to the cigarette jack under the center fascia.
    2.  
    3. Turn the ignition switch ON and power on the Hi-Scan Pro.
    4.  
    5. Select the vehicle's name.
    6.  
    7. Select AUTOMATIC TRANSAXLE.
    8.  
    9. Select RESETTING AUTO T/A VALUES and perform the procedure.
    10.  
    11. Perform the procedure by pressing F1 (REST).
    12.  

  62.  

1.6L, 2.0L & 2.4L Engines



Specific to:

Hyundai Accent 2006-2008

Hyundai Elantra 2006-2008

Hyundai Sonata 2006-2008

Hyundai Tiburon 2006-2008

Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the battery after removing the battery terminal.
  6.  
  7. Remove the air duct assembly.
  8.  
  9. Remove the air cleaner assembly by disconnecting the Air Flow Sensor (AFS) connector, the clamp, and the ECM connector.
  10.  
  11. Remove the battery tray.
  12.  
  13. Remove the ground cable from the transaxle.
  14.  
  15. Disconnect the inhibiter switch connector, solenoid valve connector, and the input shaft speed sensor connector.
  16.  
  17. Disconnect the output shaft speed sensor connector.
  18.  
  19. Remove the control cable assembly.
  20.  
  21. Remove the oil cooler hoses.
  22.  
  23. Install the special tools (09200-38001), the engine support fixture and the adapter on the engine assembly.

    Click image to see an enlarged view

    Fig. Install the special tools (09200-38001), the engine support fixture and the adapter on the engine assembly-1.6L, 2.0L and 2.4L engines

  24.  
  25. Remove the transaxle upper mounting bolts and the starter motor mounting bolts.
  26.  
  27. Remove the 4 bolts and take off the transaxle support bracket.
  28.  
  29. Remove the steering joint assembly bolt.
  30.  
  31. Remove the front wheels and tires.
  32.  
  33. Remove the side mud cover.
  34.  
  35. Remove the under shield cover.
  36.  
  37. Drain the transaxle fluid by removing the oil drain plug.
  38.  
  39. Remove the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut from the front knuckles.
  40.  
  41. Remove the roll stopper mounting bolts.
  42.  
  43. Remove the muffler hanger rubber.
  44.  
  45. Supporting the sub frame with a jack and the Special tool (09624-38000), remove the mounting bolts.
  46.  
  47. Disconnect the halfshafts from the transaxle.
  48.  
  49. Remove the drive plate mounting bolts.
  50.  
  51. Supporting the transaxle with a jack, remove the transaxle lower mounting bolts.
  52.  
  53. Lowering the jack slowly, remove the transaxle.
    WARNING
    When removing the transaxle assembly, be careful not to damage any surrounding parts or body components.

  54.  

To install:

  1. Install the transaxle lower mounting bolts after fitting the transaxle assembly into the engine assembly. Tighten to: 31-40 ft. lbs. (43-55 Nm).
  2.  
  3. Install the drive plate mounting bolts. Tighten to: 33-38 ft. lbs. (46-53 Nm).
  4.  
  5. Connect the halfshafts to the transaxle.
  6.  
  7. Supporting the sub frame with a jack and the Special tool(09624-38000), install the mounting bolts. Tighten the bolts to: 101-118 ft. lbs. (140-160 Nm).
  8.  
  9. Install the muffler hanger rubber.
  10.  
  11. Install the roll stopper mounting bolts. Tighten to: 36-47 ft. lbs. (50-65 Nm).
  12.  
  13. Install the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut to the front knuckles.
  14.  
  15. Install the under shield cover.
  16.  
  17. Install the side mud cover.
  18.  
  19. Install the front wheels and tires.
  20.  
  21. Install the steering joint assembly bolt.
  22.  
  23. Install the transaxle support bracket bolts. Tighten to: 43-58 ft. lbs. (60-80 Nm).
  24.  
  25. Install the transaxle upper mounting bolts. Tighten to: 43-58 ft. lbs. (60-80 Nm).
  26.  
  27. Install the starter motor mounting bolts. Tighten to: 28-43 ft. lbs. (39-60 Nm).
  28.  
  29. Remove the special tool (09200-38001).
  30.  
  31. Connect the transaxle oil cooler hoses to the tubes by fastening the clamps.
  32.  
  33. Install the control cable assembly.
  34.  
  35. Install the output speed sensor connector.
  36.  
  37. Connect the inhibiter switch connector, solenoid valve connector and the input shaft speed sensor connector.
  38.  
  39. Install the ground cable to transaxle.
  40.  
  41. Install the battery tray.
  42.  
  43. Install the air cleaner assembly by connecting the AFS connector, the clamp, and the ECM connector.
  44.  
  45. Install the air duct assembly.
  46.  
  47. Install the battery and the battery terminal.
  48.  
  49. Install the engine cover.
  50.  
  51. After completing the installation perform the following procedure:
    1. Adjust the shift cable.
    2.  
    3. Refill the transaxle fluid.
    4.  
    5. Clean the battery posts and cable terminals with sandpaper and grease them to prevent corrosion before installing.
    6.  
    7. When replacing the automatic transaxle, reset the automatic transaxle's values by using the High-Scan Pro.

      Connect the Hi-Scan Pro connector to the data link connector under the crash pad and power cable to the cigar jack under the center fascia
       
      Turn the ignition switch on and power on the Hi-Scan Pro
       
      Select the vehicle name
       
      Select AUTOMATIC TRANSAXLE
       
      Select RESETTING AUTO T/A VALUES and perform the procedure
       
      Perform the procedure by pressing F1 (REST)
       

    8.  

  52.  
  53. Install the transaxle control cable and adjust as follows.
    1. Move the shift lever and the transaxle range switch to the "N" Position, and install the control cable.
    2.  
    3. When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts the control cable.
    4.  
    5. Remove any free-play in the control cable by adjusting the nut and then check to see that the select lever moves smoothly.
    6.  
    7. Check to see that the control cable has been adjusted correctly.
    8.  

  54.  
  55. Fill the transaxle fluid to the proper level.
  56.  
  57. Start the vehicle, check for leaks and repair if necessary.
  58.  

2.7L, 3.3L & 3.8L Engines



Specific to:

Hyundai Azera 2006-2008

Hyundai Sonata 2006-2008

Hyundai Tiburon 2006-2008

Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative terminal from the battery.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove the intake air hose and the air cleaner assembly.
    1. Disconnect the AFS connector.
    2.  
    3. Disconnect the breather hose from air cleaner hose.
    4.  
    5. Disconnect the PCM connectors.
    6.  
    7. Remove the intake air hose and air cleaner.
    8.  

  8.  
  9. Disconnect the positive terminal from the battery and remove the battery.
  10.  
  11. Remove the transaxle oil cooler hoses.
  12.  
  13. Remove engine wiring.
    1. Disconnect the RH rear oxygen sensor connector.
    2.  
    3. Disconnect the LH rear oxygen sensor connector and the CPS connector.
    4.  

  14.  
  15. Disconnect the transaxle wire harness connector and remove transaxle control cable.
    1. Remove the wiring brackets.
    2.  
    3. After removing a transaxle bracket, remove the inhibiter switch connector and shift cable.
    4.  
    5. Remove the solenoid valve connector.
    6.  
    7. Remove the input speed sensor, output speed sensor and vehicle speed sensor connector.
    8.  
    9. Disconnect the ground wire.
    10.  

  16.  
  17. Disconnect the power steering pressure sensor connector.
  18.  
  19. Remove the power steering hose mounting bolts.
  20.  
  21. Remove the front wheels.
  22.  
  23. Disconnect the EPS connector around the left hand side front wheel.
  24.  
  25. Remove the transaxle mounting bolts.
  26.  
  27. Using the SST (09200-38001), hold the engine and transaxle assembly safely.
  28.  
  29. Remove the transaxle insulator mounting bolt.
  30.  
  31. Raise and safely support the vehicle.
  32.  
  33. Remove the undercover.
  34.  
  35. Drain the transaxle oil.
  36.  
  37. Disconnect the power steering pump hose.
  38.  
  39. Disconnect the lower arm assembly from the knuckle.
  40.  
  41. Disconnect the tie rod end ball joint from the knuckle after removing the split pin.
  42.  
  43. Disconnect the stabilizer bar link.
  44.  
  45. Remove the front roll stopper mounting bolt.
  46.  
  47. Remove the front exhaust pipe.
  48.  
  49. Remove the rear roll stopper mounting bolt.
  50.  
  51. Using the SST (09624-38000) and holding the cross member with a jack, remove the steering bolt.
  52.  
  53. Remove the cross member.
  54.  
  55. Remove the halfshaft from transaxle.
  56.  
  57. Install a jack for supporting the transaxle assembly.
  58.  
  59. Remove the transaxle under mounting bolts and the drive plate bolts.
  60.  
  61. Lifting the vehicle up or lowering the jack slowly, remove the transaxle assembly.
  62.  

To install:

  1. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
  2.  
  3. Tighten the transaxle under mounting bolts. Tighten to:
    1. Bolts (A): 25-30 ft. lbs. (34-41.2 Nm).
    2.  
    3. Bolt (B): 33-38 ft. lbs. (45-52 Nm).

      Click image to see an enlarged view

      Fig. Tighten the transaxle under mounting bolts (A, B)-2.7L, 3.3L, and 3.8L engines

    4.  

  4.  
  5. Remove the jack and insert the halfshafts.
  6.  
  7. Supporting the cross member with the SST (09624-38000), tighten the steering column bolt and the cross member mounting bolts.
  8.  
  9. Tighten the rear roll stopper mounting bolt to: 36-47 ft. lbs. (49-64 Nm).
  10.  
  11. Install the front exhaust pipe.
  12.  
  13. Tighten the front roll stopper mounting bolt to: 36-47 ft. lbs. (49-64 Nm).
  14.  
  15. Install the steering bar tie rod, the stabilizer bar link, and the lower arm assembly.
  16.  
  17. Clamp the power steering pump hose.
  18.  
  19. Install the undercover.
  20.  
  21. After lowering the vehicle, tighten the transaxle insulator mounting bolt (A). Tighten to: 47-62 ft. lbs. (63-83 Nm).
  22.  
  23. Tighten the transaxle mounting bolts (B, C).
    1. Bolts (B): 24-36 ft. lbs. (32-49 Nm).
    2.  
    3. Bolts (C): 47-62 ft. lbs. (64-83 Nm).

      Click image to see an enlarged view

      Fig. Tighten the transaxle under mounting bolts (B, C)-2.7L, 3.3L, and 3.8L engines

    4.  

  24.  
  25. Remove the SST (09200-38001) holding the engine and transaxle assembly.
  26.  
  27. Connect the EPS connector and install the front wheels and tires.
  28.  
  29. Install the power steering hose mounting bolts.
  30.  
  31. Connect the power steering pressure sensor connector.
  32.  
  33. Connect the transaxle wire harness connector and the control cable.
    1. Install the wiring brackets.
    2.  
    3. Connect the inhibitor switch connector and the shift cable and install the transaxle bracket.
    4.  
    5. Connect the solenoid valve connector.
    6.  
    7. Connect the input/output speed sensor connectors and vehicle speed sensor connector.
    8.  
    9. Connect the ground wire.
    10.  

  34.  
  35. Connect the engine wiring.
    1. Connect the RH rear oxygen sensor connector.
    2.  
    3. Connect the LH rear oxygen sensor connector and the CPS connector.
    4.  

  36.  
  37. Clamp the transaxle oil cooler hoses(A).
  38.  
  39. After disconnecting the positive terminal from the battery, remove the battery.
  40.  
  41. Install the intake air hose and the air cleaner assembly.
    1. Connect the AFS connector.
    2.  
    3. Clamp the breather hose from the air cleaner hose.
    4.  
    5. Connect the PCM connectors.
    6.  
    7. Install the intake air hose and the air cleaner assembly.
    8.  

  42.  
  43. Install the engine cover.
  44.  
  45. Connect the negative terminal on the battery.
  46.  
  47. Fill the transaxle fluid to the proper level.
  48.  
  49. Start the vehicle, check for leaks and repair if necessary.
  50.  

 
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