Hyundai Coupes/Sedans 1986-1993 Repair Guide

Transaxle

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REMOVAL & INSTALLATION



1986-89 Excel

See Figure 1

The transaxle and converter must be removed and installed as an assembly.

  1. Remove the battery and battery tray.
  2.  
  3. Disconnect the throttle control cable at the carburetor and the manual control cable at the transaxle.
  4.  
  5. Disconnect from the transaxle: the inhibitor switch (neutral safety) connector, fluid cooler hoses and the four upper bolts connecting the engine to the transaxle.
  6.  
  7. Jack up the car and support on jackstands.
  8.  
  9. Remove the front wheels. Remove the engine splash shield.
  10.  
  11. Drain the transaxle fluid.
  12.  
  13. Disconnect the stabilizer bar at the lower arms, and disconnect the control arms from the body. Remove the right and left driveshafts from the transaxle case.
  14.  
  15. Disconnect the speedometer cable. Remove the starter motor.
  16.  
  17. Remove the lower cover from the converter housing. Remove the 3 bolts connecting the converter to the engine drive plate.
  18.  

Never support the full weight of the transaxle on the engine drive plate.

  1. Turn and force the converter back and away from the engine drive plate.
  2.  
  3. Support the weight of the engine from above (chain hoist). Support the transaxle and remove the remaining mounting bolts.
  4.  
  5. Remove the transaxle mount insulator bolt and remove the transaxle mounting bracket from the transaxle.
  6.  
  7. Remove (slide away from the engine to the right) and lower the transaxle and converter as an assembly.
  8.  

To install:
  1. Raise the transaxle and converter assembly into place and install the transaxle mounting bracket and insulator bolt. Torque the insulator bolt to 31-40 ft. lbs.
  2.  
  3. Tension the engine hoist and support the transaxle.
  4.  
  5. Install the bell housing bolts and torque them to specification. Use the illustration for bolt locations and corresponding torque values.
  6.  



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Fig. Fig. 1: Automatic transaxle bolt torque and size specifications-1986-89 Excel

  1. Install the 3 converter-to-drive plate bolts and torque them 25-30 ft. lbs.
  2.  
  3. Install the converter housing lower cover.
  4.  
  5. Install the starter motor.
  6.  
  7. Connect the speedometer cable to the transaxle.
  8.  
  9. Install the right and left driveshafts.
  10.  
  11. Connect the lower control arms to the body and stabilizer bar to the control arms.
  12.  
  13. Install the engine splash shield and mount the front wheels.
  14.  
  15. Lower the car.
  16.  
  17. Install the 4 upper engine-to-transaxle bolts and torque to specification.
  18.  
  19. Connect the fluid cooler hoses and the inhibitor switch connector to the transaxle.
  20.  
  21. Connect the manual control cable to the control lever on the transaxle. Adjust the control cable and inhibitor switch as described in this section.
  22.  
  23. Connect the throttle cable to the carburetor.
  24.  
  25. Install the battery tray and battery.
  26.  
  27. Fill the transaxle to the proper level with Dexron®II automatic transmission fluid.
  28.  

1990-93 Excel, Elantra and Scoupe

See Figures 2, 3, 4, 5 and 6



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Fig. Fig. 2: Transaxle mount bolt locations



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Fig. Fig. 3: Remove the center member for transaxle removal



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Fig. Fig. 4: With the bell housing cover removed, rotate the converter to remove the converter bolts

  1. Drain the fluid from the transaxle.
  2.  
  3. Remove the entire air cleaner assembly including the air intake and breather hoses. Disconnect the air flow sensor connector and the purge control solenoid valve connector and hoses. Label all the connections to avoid confusion during assembly.
  4.  
  5. Disconnect the cooler supply and return lines from the transaxle. Plug the line openings to prevent the entry of dirt and foreign matter.
  6.  
  7. Disconnect the control cable from the shift lever.
  8.  
  9. Disconnect the speedometer cable from the transaxle. Route the cable off to the side and out of the way.
  10.  
  11. Unplug the connectors to the solenoid valves, inhibitor switch, pulse generators, kickdown servo switch and oil temperature sensor.
  12.  
  13. Working from the top of the transaxle, remove the upper transaxle-to-engine mounting bolts.
  14.  
  15. Remove the transaxle mounting bracket.
  16.  
  17. Support the transaxle with a jack and remove the center member mounting bolts.
  18.  

To avoid placing excessive pressure on the oil pan, support the transaxle in a wide area.

  1. Raise the front of the vehicle and support on jackstands.
  2.  
  3. Remove both wheels and both axle-end cotter pins, nuts and washers.
  4.  
  5. Remove the ball joint nuts and separate the ball joints from the knuckles.
  6.  
  7. Remove the driveshaft from the transaxle.
  8.  

If desired, the axles may be left attached to the vehicle. Some prefer to have them out of the way. If left attached, be sure to suspend them with a strong rope or wire; if they hang free, the CV-joints or boots could get damaged.

  1. Unbolt and remove the bell housing cover.
  2.  
  3. Place the shifter lever in the N position. Remove the 3 special bolts attaching the torque converter to the drive plate. To remove these bolts, engage the crankshaft pulley nut with a socket and turn the crankshaft until each bolt comes into view. Remove each bolt with the proper size box end wrench by working through the bell housing cover access hole.
  4.  
  5. After the drive plate bolts are removed, reinstall the center member temporarily.
  6.  
  7. Remove the lower engine-to-transaxle mounting bolts and lower the transaxle from the engine.
  8.  

To install:
  1. Place the transaxle on the transaxle jack securely and install onto the engine, using the dowels as guides. Make sure all heater tube clamps, wires, etc. are out of the way or it will not be possible to install the transaxle flush with the block.
  2.  
  3. Install the lower transaxle-to-engine bolts. Torque the bolts to specification (see illustration for bolt locations and torque values).
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Automatic transaxle bolt torque and size specifications-1990-93 Excel, Elantra and Scoupe



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Fig. Fig. 6: Automatic transaxle bolt torque and size specifications-Sonata with KM-175 transaxle

  1. Remove the center member.
  2.  
  3. Install the torque converter-to-drive plate bolts and torque them to 34-39 ft. lbs.
  4.  
  5. Install the bell housing cover and torque the bolts to 7-9 ft. lbs.
  6.  
  7. Install the driveshafts.
  8.  
  9. Connect the ball joints to the steering knuckles.
  10.  
  11. Install the front axle, nuts and washers. Mount the front wheels.
  12.  
  13. Lower the vehicle.
  14.  
  15. Install the center member.
  16.  
  17. Install the transaxle mounting bracket and torque the bolts to 43-58 ft. lbs.
  18.  
  19. Install the upper transaxle mounting bolts (see illustration for bolt locations and torque values).
  20.  
  21. Plug in all the transaxle electrical connectors.
  22.  
  23. Connect the speedometer cable to the transaxle.
  24.  
  25. Connect the control cable to the shift lever. Adjust the control cable as described in this section.
  26.  
  27. Connect the cooler supply and return lines to the transaxle.
  28.  
  29. Install the air cleaner assembly.
  30.  
  31. Fill the transaxle to the proper level.
  32.  

Sonata

See Figure 7

  1. Remove the drain plug and drain the transmission fluid.
  2.  
  3. Remove the entire air cleaner assembly including the air intake and breather hoses. Unplug the air flow sensor connector and the purge control solenoid valve connector and hoses.
  4.  
  5. Disconnect the manual control cable from the control lever.
  6.  
  7. Disconnect the speedometer cable from the transaxle.
  8.  
  9. Unplug the connectors to the solenoid valves, inhibitor switch, pulse generators, kickdown servo switch, oil temperature sensor and unplug the engine wiring harness.
  10.  
  11. Remove the starter motor.
  12.  
  13. Raise the front of the vehicle and support on jackstands.
  14.  
  15. Remove the left side under cover.
  16.  
  17. Remove the stabilizer bar.
  18.  
  19. Remove both wheels and both axle-end cotter pins, nuts and washers.
  20.  
  21. Remove the ball joint nuts and separate the ball joints from the knuckles.
  22.  
  23. Remove the driveshaft from the transaxle.
  24.  

If desired, the axles may be left attached to the vehicle. Some prefer to have them out of the way. If left attached, be sure to suspend them with a strong rope or wire; if they hang free, the CV-joints or boots could get damaged.

  1. Unbolt and remove the bell housing inspection cover.
  2.  
  3. Support the transaxle with a transmission jack and remove the center member from the crossmember.
  4.  
  5. Remove the lower cover from the converter housing. Remove the three bolts connecting the converter to the engine drive plate.
  6.  

Never support the full weight of the transaxle on the engine drive plate.

  1. Turn and force the converter back and away from the engine drive plate.
  2.  
  3. Remove and plug the oil cooler hoses.
  4.  
  5. Remove the plastic outer cover caps in the right fender shield. There are four of them. After removing the caps, remove the mounting bolts under them. These bolts attach the transmission mounting bracket to the body.
  6.  
  7. Support the engine and remove the upper engine-to-transaxle bolts. If it is necessary to remove heater hoses to gain access to the upper bolts, drain the radiator first.
  8.  
  9. Remove the remaining transaxle-to-engine bolts.
  10.  
  11. Slide the transaxle assembly to the right and tilt it down to remove it from the vehicle.
  12.  

To install:
  1. Install the torque converter to the transaxle. The converter is correctly installed when the distance from the ring gear to the bell housing surface is 12mm.
  2.  
  3. Place the transaxle on the transaxle jack securely and install the transaxle to the engine using the dowels as guides. Make sure all heater tube clamps, wires, etc. are out of the way or it will not be possible to install the transaxle flush with the block.
  4.  
  5. Install the lower transaxle-to-engine bolts. Torque the bolts to specification (see illustration for bolt locations and torque values).
  6.  



Click image to see an enlarged view

Fig. Fig. 7: Automatic transaxle bolt torque and size specifications-Sonata with KM-177 transaxle

  1. Install the 4 transaxle-to-body mounting bolts and torque the to 43-57 ft. lbs. Install the 4 plastic caps.
  2.  
  3. Connect the oil cooler lines.
  4.  
  5. Turn and push the torque converter towards the drive plate.
  6.  
  7. Apply Loctite® to the threads and install the three torque converter bolts. Torque the bolts to specification (see illustration).
  8.  
  9. Install the torque converter inspection plate.
  10.  
  11. Install the transaxle center member onto the crossmember. Torque bolts to 58-71 ft. lbs.
  12.  
  13. Install the bell housing inspection cover and torque the retaining bolts to 7-9 ft. lbs.
  14.  
  15. Install the driveshafts. Make sure the shafts are completely seated in place and an circlips and snaprings are securely in place.
  16.  
  17. Install the ball joints to the knuckles and torque the locknuts to 43-52 ft. lbs.
  18.  
  19. If removed, install the axle-end washers, nuts and cotter pins. Torque the nuts to 145-188 ft. lbs.
  20.  
  21. Install the stabilizer bar.
  22.  
  23. Install the left side under cover. Lower the vehicle.
  24.  
  25. Install the starter motor.
  26.  
  27. Connect all the engine wiring harness connectors.
  28.  
  29. Install the speedometer cable.
  30.  
  31. Install the manual control cable and secure the cotter pin.
  32.  
  33. Install the air cleaner assembly.
  34.  
  35. Fill the transaxle to the proper level. Road test the vehicle.
  36.  

 
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