Hyundai Cars 2006-2008

Transaxle Removal & Installation

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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 connections.
  6.  
  7. Remove the air duct assembly.
  8.  
  9. Remove the air cleaner assembly by disconnecting the clamp and the ECM connector.
  10.  
  11. Remove the ground cable from the transaxle.
  12.  
  13. Disconnect the vehicle speed sensor and the back lamp switch integrated connector.
  14.  
  15. Remove the control cable assembly by removing the snap pins and clips.
  16.  
  17. Remove the control cable bracket.
  18.  
  19. Using the special tool (09200-38001), support the engine assembly safely.

    Click image to see an enlarged view

    Fig. Using the special tool (09200-38001) to support the engine assembly-1.6L, 2.0L and 2.4L engines

  20.  
  21. Remove the transaxle upper mounting bolts and the starter motor mounting bolts.
  22.  
  23. After removing the bolts, take the transaxle insulator mounting bracket off.
  24.  
  25. Remove the steering joint assembly bolt.
  26.  
  27. Raise and safely support the vehicle.
  28.  
  29. Remove the front wheels and tires.
  30.  
  31. Remove the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut from the front knuckles.
  32.  
  33. Remove the under shield cover.
  34.  
  35. Remove the roll stopper mounting bolts.
  36.  
  37. Disconnect the muffler hanger rubber.
  38.  
  39. Supporting the sub frame (A) with a jack and the Special tool (09624-38000), remove the mounting bolts.

    Click image to see an enlarged view

    Fig. Support the sub frame (A) with a jack and the Special tool (09624-38000) and remove the mounting bolts-1.6L, 2.0L and 2.4L engines

  40.  
  41. Disconnect the halfshafts from the transaxle.
  42.  
  43. Remove the clutch release cylinder assembly.
  44.  
  45. Supporting the transaxle with a jack, remove the transaxle lower mounting bolts.
  46.  
  47. Lowering the jack slowly, remove the transaxle.
  48.  

To install:

  1. Fit the transaxle assembly to the engine assembly.
  2.  
  3. Install the transaxle lower mounting bolts. Tighten to:
    1. Bolts (A): 22-30 ft. lbs. (30-42 Nm).
    2.  
    3. Bolts (B): 31-40 ft. lbs. (43-55 Nm).

      Click image to see an enlarged view

      Fig. Install the transaxle lower mounting bolts-1.6L, 2.0L and 2.4L engines

    4.  

  4.  
  5. Install the clutch release cylinder assembly.
  6.  
  7. Connect the halfshafts to the transaxle.
  8.  
  9. Supporting the sub frame with a jack and the Special tool(09624-38000), install the mounting bolts. Tighten to: 101-118 ft. lbs. (140-160 Nm).
  10.  
  11. Install the muffler hanger rubber.
  12.  
  13. Install the roll stopper bracket bolts. Tighten to: 36-47 ft. lbs. (50-65 Nm).
  14.  
  15. Install the under shield cover.
  16.  
  17. Install the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut to the front knuckles.
  18.  
  19. Install the front wheels and tires.
  20.  
  21. Install the steering joint assembly bolt. Tighten to: 13-18 ft. lbs. (18-25 Nm).
  22.  
  23. Install the transaxle insulator mounting bracket bolts. Tighten to: 43-58 ft. lbs. (60-80 Nm).
  24.  
  25. Remove the special tool (09200-38001).
  26.  
  27. Install the transaxle upper mounting bolts. Tighten to: 43-60 ft. lbs. (60-80 Nm).
  28.  
  29. Install the starter motor mounting bolts. Tighten to: 28-43 ft. lbs. (39-60 Nm).
  30.  
  31. Install the control cable bracket. Tighten to: 11-16 ft. lbs. (15-22 Nm).
  32.  
  33. Connect the vehicle speed sensor and the back lamp switch integrated connector.
  34.  
  35. Install the control cable assembly by installing the clips and pins.
  36.  
  37. Install the ground cable to the transaxle.
  38.  
  39. Install the air cleaner assembly and the ECM connector.
  40.  
  41. Install the air duct assembly.
  42.  
  43. Install the battery and connect the battery terminals.
  44.  
  45. Install the engine cover.
  46.  

2.7L Engine



Specific to:

Hyundai Tiburon 2006-2008

Hyundai recommends that the engine and manual transaxle be removed as a single unit. Refer to Engine Assembly, removal & installation.

 
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