Hyundai Coupes/Sedans 1986-1993 Repair Guide

Transaxle

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REMOVAL & INSTALLATION



If the vehicle is going to be rolled while the halfshafts are out of the vehicle, obtain 2 outer CV-joints or proper equivalent tools and install to the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable.

1986-89 Excel

See Figures 1 through 5



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Fig. Fig. 1: Selector control valve connector on 1986-89 Excel with 5 speed transaxle

  1. Disconnect the negative battery cable.
  2.  



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Fig. Fig. 2: Upper transaxle-to-engine bolts on 1986-89 Excel

  1. Disconnect or remove from the transaxle: the clutch cable, speedometer cable, back-up light harness, starter motor (remove) and the four upper bolts connecting the engine to the transaxle. On cars with a 5-speed transaxle, disconnect the selector control valve.
  2.  



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Fig. Fig. 3: Lower transaxle-to-engine bolts on 1986-89 Excel



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Fig. Fig. 4: Transaxle mount insulator bolt on 1986-89 Excel



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Fig. Fig. 5: Bolt size, location and torque specifications-1986-89 Excel

  1. Raise the vehicle and support it safely on jackstands.
  2.  
  3. Remove the front wheels. Remove the splash shield. Drain the transaxle fluid into a suitable waste container.
  4.  
  5. Remove the shift rod and extension rod. It may be necessary to remove any heat shields that can interfere with your progress.
  6.  
  7. Remove the stabilizer bar from the lower arm and disconnect the lower arm from the body side.
  8.  
  9. Remove the right and left driveshafts from the transaxle case. See drive axle removal in this section.
  10.  
  11. Disconnect the range selector cable (if equipped). Remove the engine rear cover.
  12.  
  13. Support the weight of the engine from above (chain hoist). Support the transaxle and remove the remaining lower mounting bolts.
  14.  
  15. Remove the transaxle mount insulator bolt.
  16.  
  17. Remove (slide back and away from the engine) and lower the transaxle on a suitable transmission jack.
  18.  

To install:
  1. Maneuver the transaxle into position under the engine and raise into place using the transmission jack. Make sure the weight of the engine is supported by the chain hoist.
  2.  
  3. Install the transaxle insulator and the lower transaxle mounting bolts. Tighten them enough to support the transaxle, then torque the bolts to specification (see fig5 for bolt location and torque values).
  4.  
  5. Install the engine rear cover and connect the range selector cable (if equipped).
  6.  
  7. Connect the driveshafts to the transaxle case. Use new retaining rings.
  8.  
  9. Connect the lower control arm. Connect the stabilizer bar to the lower arm. Torque the stabilizer bar bolts to 4 ft. lbs. (5.5 Nm) and the lower control arm bolts to 69-87 ft. lbs. (93-117 Nm).
  10.  
  11. Install any heat shield at this time. Connect the extension and shift rods.
  12.  
  13. Mount the front wheels and lower the vehicle.
  14.  
  15. If equipped with a 5-speed, connect the selector control valve mechanism.
  16.  
  17. Install the remaining four upper transaxle to engine bolts and torque to specification.
  18.  
  19. Install the starter motor.
  20.  
  21. Connect the back-up fight harness, speedometer cable and clutch cable to the transaxle.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Fill the transaxle to the proper level with the proper fluid. Move the shift lever through all the gears to make sure they engage properly.
  26.  

1990-93 Excel, Elantra and Scoupe

See Figures 6 through 11

If the vehicle is going to be rolled while the halfshafts are out of the vehicle, obtain 2 outer CV-joints or proper equivalent tools and install to the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable.

  1. Disconnect the negative battery cable. Remove the air cleaner assembly, battery and battery tray as required.
  2.  
  3. On 5-speed transaxle, disconnect the electrical connector for the selector control valve.
  4.  

The actuator-to-shaft coupling pin collar is not reusable; replace it.



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Fig. Fig. 6: Shift and select cables-1990-93 Excel, Elantra and Scoupe



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Fig. Fig. 7: Speedometer cable attaching bolt-1990-93 Excel, Elantra and Scoupe



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Fig. Fig. 8: Upper transaxle mounting bolts-1990-93 Excel, Elantra and Scoupe

  1. Disconnect and remove the speedometer cable.
  2.  
  3. If equipped with a cable operated clutch, disconnect the clutch cable from the transaxle assembly.
  4.  
  5. If equipped with a hydraulically operated clutch, remove the clevis pin connecting the slave cylinder to the release fork shaft and remove the slave cylinder mounting bolts. Remove the bolts attaching the hydraulic line support bracket to the transaxle. Remove and support the slave cylinder assembly out of the way with a length of mechanics wire.
  6.  



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Fig. Fig. 9: Bell housing cover bolts-1990-93 Excel, Elantra and Scoupe



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Fig. Fig. 10: Manual transaxle mounting-1990-93 Excel



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Fig. Fig. 11: Manual transaxle mounting-Elantra and Scoupe

  1. Disconnect the back-up lamp electrical connector. Remove the starter motor electrical harness.
  2.  
  3. Remove the transaxle mounting bolts accessible from the top side of the transaxle.
  4.  
  5. Unbolt and remove the starter motor.
  6.  
  7. Raise the vehicle and support it safely. Then, remove the splash shield from under the engine. Drain the transaxle fluid.
  8.  
  9. Disconnect the extension rod and the shift rod at the transaxle end and lower them.
  10.  
  11. Disconnect the stabilizer bar at the lower control arm.
  12.  
  13. Remove the halfshafts from the transaxle assembly.
  14.  
  15. Support the transaxle from below with a floor jack. Make sure the support is widely enough spread that the transaxle pan will not be damaged. Then, remove the attaching bolts and the bell housing cover.
  16.  
  17. Remove the lower bolts attaching the transaxle to the engine.
  18.  
  19. Remove the transaxle insulator mount bolt. Remove the cover from inside the right fender shield and remove the transaxle support bracket.
  20.  
  21. Remove the transaxle mount bracket.
  22.  
  23. Pull the assembly away from the engine and lower it from the vehicle.
  24.  

To install:
  1. Install the transaxle to the engine and install the mounting bolts. Tighten the mounting bolts as follows:

    M10-7T engine-to-transaxle bolts-35 ft. lbs. (48 Nm)
     
    M8-10T engine-to-transaxle bolts-25 ft. lbs. (34 Nm)
     

  2.  
  3. When installing the halfshafts, use new circlips on the axle ends. Take care to get the inboard joint parts straight, not bent relative to the axle. Care must be taken to ensure that the oil seal lip of the transaxle is not damaged by the serrated part of the driveshaft.
  4.  
  5. Install the undercover.
  6.  
  7. Install the mounting brackets and torque the mounting bracket bolt to 40 ft. lbs. (54 Nm).
  8.  
  9. Install the starter making sure to fasten the ground wire with the upper fastener and the harness fastener with the lower fastener.
  10.  
  11. Connect the back-up light switch connector and speedometer cable.
  12.  
  13. Install the clutch and shifter actuation components. If the hydraulic system was opened, it should be bled after installation.
  14.  
  15. Install the air cleaner and battery.
  16.  
  17. Make sure the vehicle is level when refilling the transaxle. Use Hypoid gear oil or equivalent, GL-4 or higher.
  18.  
  19. Connect the negative battery cable and check the transaxle for proper operation. Make sure the reverse lights come on when in R.
  20.  

Sonata

See Figure 12



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Fig. Fig. 12: Manual transaxle mounting-Sonata

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the clutch release cylinder from the transaxle case as described later in this section.
  4.  
  5. Drain the transaxle oil into a suitable waste container.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the pin clips and cotter pins and disconnect the select and shift cables from the control levers.
  10.  
  11. Disconnect the back-up lamp switch connector and route the wiring harness off to the side and out of the way.
  12.  
  13. Disconnect the speedometer cable from the transaxle.
  14.  
  15. Disconnect and label the starter wiring. Remove the starter.
  16.  
  17. Jack up the car, support on jackstands and remove the front wheels. Remove any interfering shield or undercover.
  18.  
  19. Remove the left and right driveshafts as described later in this section.
  20.  
  21. Unbolt and remove the bell housing cover.
  22.  
  23. Connect a chain hoist or equivalent to the engine lifting bracket. Tension the hoist to support the weight of the engine.
  24.  
  25. Support the bottom of the transaxle with a transmission jack.
  26.  
  27. Remove the 4 plastic mounting bracket bolt access caps and remove the 4 transaxle mounting bracket bolts.
  28.  
  29. Remove the upper and lower transaxle-to-engine and engine-to-transaxle mounting bolts.
  30.  
  31. Lower the transaxle away from the engine.
  32.  

To install:
  1. Raise the transaxle up and onto the engine. Align the bolt holes and install the upper and lower mounting bolts. Install the four transaxle bracket bolts. Make sure the weight of the engine is supported with the chain hoist. Torque all bolts to specification. Install the four plastic caps.
  2.  
  3. Install the bell housing cover.
  4.  
  5. Install the driveshafts using new clips.
  6.  
  7. Install any shield or under cover that was removed.
  8.  
  9. Mount the front wheels and lower the vehicle.
  10.  
  11. Install the starter and connect the starter wiring.
  12.  
  13. Connect the speedometer cable to the transaxle.
  14.  
  15. Plug in the back-up light switch harness.
  16.  
  17. Connect the shift and select cables to their respective control levers. Adjust the cable tension.
  18.  
  19. Install the air cleaner assembly.
  20.  
  21. Install the clutch release cylinder. Make sure the hose fittings are tight.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Fill the transaxle and clutch master cylinder to the proper level with the specified fluid. Move the shift lever through all the gears to make sure they engage and disengage properly.
  26.  

 
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