Hyundai Coupes/Sedans 1986-1993 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1 and 2

Cable Operated System


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Fig. Fig. 1: 1986-89 Excel clutch components

  1. Remove the transaxle. Insert the forward end of an old transaxle input shaft or a clutch disc guide tool into the splined center of the clutch disc, pressure plate and the pilot bearing in the crankshaft. This will keep the disc from dropping when the pressure plate is removed from the flywheel.
  2.  
  3. Loosen the clutch mounting bolts alternately and diagonally in very small increments, no more than 2 turns at a time, so as to avoid warping the cover flange.
  4.  
  5. Remove the pressure plate and disc.
  6.  
  7. Remove the return clip and the clutch release bearing.
  8.  
  9. Insert tool 09414-24000 in the spring pin and attach the round nut to the end of the tool. While holding the shaft of the special tool, rotate the sleeve with a wrench to force the spring pin out.
  10.  
  11. Remove the clutch release shaft, packings, return spring and the release fork.
  12.  

To install:
  1. Apply a light coating of multi-purpose grease to the release fork shaft and the throw out bearing contact surfaces.
  2.  
  3. Align the lock pin holes of the release fork and shaft and drive 2 new spring pins into the holes. Make sure the spring pin slot is at right angles to the centerline of the control shaft.
  4.  
  5. Apply grease into the groove in the release bearing and install bearing into the front bearing retainer in the transaxle. Install the return clip to the release bearing and fork.
  6.  



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Fig. Fig. 2: When removing the clutch disc, insert a pilot shaft to prevent the disc from falling

  1. Make sure the surfaces of the pressure plate and flywheel are wiped clean of grease and lightly sand them with crocus cloth. Lightly grease the clutch disc and transaxle input shaft splines making sure not to allow any grease to contact the clutch disc material or clutch slip may result.
  2.  
  3. Locate the clutch disc on the flywheel with the stamped mark facing outward. Use a clutch disc guide or old input shaft to center the disc on the flywheel and then install the pressure plate over it. Install the bolts and tighten them evenly. Tighten them in increments of 2 turns or less to avoid warping the pressure plate. Torque to 11-15 ft. lbs. (15-21 Nm).
  4.  
  5. Remove the clutch disc centering tool. Install the transaxle. Adjust the clutch free-play.
  6.  

Hydraulic System

See Figures 3, 4 and 5



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Fig. Fig. 3: Spring pin removal-1990-93 Excel



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Fig. Fig. 4: Clutch disc components-1990-93 Excel



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Fig. Fig. 5: Clutch components-Elantra, Scoupe and Sonata

ELANTRA
  1. Disconnect the negative battery cable. Raise and safely support the vehicle.
  2.  
  3. Remove the transaxle assembly from the vehicle.
  4.  
  5. Remove the pressure plate attaching bolts. If the pressure plate is to be reused, loosen the bolts in succession, 1 or 2 turns at a time to prevent warping the cover flange.
  6.  
  7. Remove the pressure plate release bearing assembly and the clutch disc. Do not use solvent to clean the bearing.
  8.  
  9. Inspect the condition of the clutch components and replace any worn parts.
  10.  

To install:
  1. Inspect the flywheel for heat damage or cracks. Resurface or replace the flywheel, as required. Install the flywheel using new bolts.
  2.  
  3. Using the proper alignment tool, install the clutch disc to the flywheel. Install the pressure plate assembly and tighten the pressure plate bolts evenly to 14 ft. lbs. (22 Nm). Remove the alignment tool.
  4.  
  5. Apply a very light coat of high temperature grease to the clutch fork at the ball pivot and where the fork contacts the bearing. Also a little bit of grease can be applied to the end of the release cylinder's pushrod and to the pushrod hole on the fork. Apply a light coat of grease on the transaxle input shaft splines.
  6.  
  7. Install a new clutch release bearing. Pack its inner surface with grease.
  8.  
  9. Install the transaxle assembly and check for proper clutch operation.
  10.  

EXCEPT ELANTRA
  1. Disconnect the negative battery cable. Raise and safely support the vehicle.
  2.  
  3. Remove the transaxle assembly from the vehicle.
  4.  
  5. Remove the pressure plate attaching bolts. If the pressure plate is to be reused, loosen the bolts in succession, 1 or 2 turns at a time to prevent warping the cover flange.
  6.  
  7. Remove the pressure plate and disc.
  8.  
  9. Remove the return clip and the clutch release bearing.
  10.  
  11. Insert tool 09414-24000 in the spring pin and attach the round nut to the end of the tool. While holding the shaft of the special tool, rotate the sleeve with a wrench to force the spring pin out.
  12.  
  13. Remove the clutch release shaft, packings, return spring and the release fork.
  14.  

To install:
  1. Apply a light coating of multipurpose grease to the release fork shaft and the throw out bearing contact surfaces.
  2.  
  3. Align the lock pin holes of the release fork and shaft and drive 2 new spring pins into the holes. Make sure the spring pin slot is at right angles to the centerline of the control shaft.
  4.  
  5. Apply grease into the groove in the release bearing and install bearing into the front bearing retainer in the transaxle. Install the return clip to the release bearing and fork.
  6.  
  7. Make sure the surfaces of the pressure plate and flywheel are wiped clean of grease and lightly sand them with crocus cloth. Lightly grease the clutch disc and transaxle input shaft splines making sure not to allow any grease to contact the clutch disc material or clutch slip may result.
  8.  
  9. Locate the clutch disc on the flywheel with the stamped mark facing outward. Use a clutch disc guide or old input shaft to center the disc on the flywheel and then install the pressure plate over it. Install the bolts and tighten them evenly. Tighten them in increments of 2 turns or less to avoid warping the pressure plate. Torque to 11-15 ft. lbs. (15-21 Nm).
  10.  
  11. Remove the clutch disc centering tool. Install the transaxle. Adjust the clutch free-play.
  12.  

 
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