Hyundai Coupes/Sedans 1994-1998 Repair Guide

Manual Transaxle Assembly

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REMOVAL & INSTALLATION



See Figures 1 through 22



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Fig. Fig. 1: The backup light switch connector is located at the top of the transaxle



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Fig. Fig. 2: Remove the E-clip from the clutch release lever....



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Fig. Fig. 3: ....remove the pin and separate the lever from the clutch slave cylinder pushrod



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Fig. Fig. 4: Unbolt the clutch slave cylinder....



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Fig. Fig. 5: ....and carefully remove. Take note, the hydraulic line is still attached in this photograph



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Fig. Fig. 6: Disconnect the speedometer cable by unscrewing the attaching nut and pulling the cable from the transaxle



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Fig. Fig. 7: Remove the cotter pin from the shift cable pin....



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Fig. Fig. 8: ....remove the shift cable washer....



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Fig. Fig. 9: ....and remove the cable from the pin



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Fig. Fig. 10: The shift cables are attached to the transaxle by a bracket....



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Fig. Fig. 11: ....matchmark the cables prior to removal...



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Fig. Fig. 12: ....spread the bracket ends and remove the cable



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Fig. Fig. 13: The starter must be removed prior to removal of the transaxle assembly



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Fig. Fig. 14: The transaxle mounting bracket is attached between the transaxle and the chassis....



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Fig. Fig. 15: ....mount to transaxle bolts are accessible from the top of the transaxle....



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Fig. Fig. 16: ....while mount to chassis bolts are hidden behind caps....



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Fig. Fig. 17: ....and accessible from inside the fender well



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Fig. Fig. 18: Once disconnected, the mount can best be removed from the under side of the vehicle



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Fig. Fig. 19: The transaxle also has an insulator which must be disconnected prior to removal



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Fig. Fig. 20: Remove the bell housing cover to gain access to the clutch



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Fig. Fig. 21: The half shafts can be carefully pryed from the transaxle. Caution should be taken not to damage seals



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Fig. Fig. 22: When jacking the transmission, insert a large piece of wood under the largest part of the case for support

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the transaxle oil.
  4.  
  5. Remove the air duct and air cleaner assembly, as required.
  6.  
  7. Disconnect the backup light switch connector.
  8.  
  9. Disconnect the clutch release mechanism and remove the clutch release cylinder.
  10.  
  11. Disconnect the speedometer cable.
  12.  
  13. Remove the pin clips and cotter pins and disconnect the select and shift cables from the control levers.
  14.  
  15. Label and disconnect the starter wiring harness. Remove the starter.
  16.  
  17. Raise and support the vehicle safely.
  18.  
  19. Disconnect the halfshafts.
  20.  
  21. Unbolt and remove the bell housing cover.
  22.  
  23. Support the bottom of the transaxle with a transmission jack.
  24.  
  25. Support the engine by the engine lifting tabs and remove the transaxle mounting brackets and insulator.
  26.  
  27. Remove the transaxle-to-engine bolts.
  28.  
  29. Slide the transaxle back and then lower it away from the engine.
  30.  

To install:
  1. Raise the transaxle into position on the engine.
  2.  
  3. Install the transaxle-to-engine bolts. Tighten M8 bolts to 6-7 ft. lbs. (8-10 Nm), M10 bolts to 22-25 ft. lbs. (30-35 Nm) and M12 bolts to 32-39 ft. lbs. (43-55 Nm).
  4.  
  5. Install the transaxle mounting brackets and tighten bolts to 65-80 ft. lbs. (90-110 Nm).
  6.  
  7. Install the bell housing cover and tighten bolts to 6-7 ft. lbs. (8-10 Nm).
  8.  
  9. Connect the halfshafts.
  10.  
  11. Lower the vehicle.
  12.  
  13. Install the starter and connect the starter wiring harness.
  14.  
  15. Connect the select and shift cables. Install new pin clips and cotter pins.
  16.  
  17. Connect the speedometer cable.
  18.  
  19. Install the clutch release cylinder and connect the clutch release mechanism.
  20.  
  21. Connect the backup light switch connector.
  22.  
  23. Install the air duct and air cleaner assembly, as required.
  24.  
  25. Fill the transaxle with oil.
  26.  
  27. Connect the negative battery cable.
  28.  

 
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