Hyundai Santa Fe 2001-05

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner duct
     
    Air cleaner and air flow hose
     
    Back-up light connector
     
    Clutch line and clip
     
    Clutch release cylinder
     
    Speedometer cable
     
    Gear select or shift cables
     
    Starter motor mounting bolts
     
    Transaxle upper bolts
     

  6.  
  7. Attach an engine support fixture to the engine.

    Transaxle mounting bracket and insulator
     
    Front wheels
     
    Tie rod end, lower ball joint and drive shaft
     
    Gear box u-joint bolt and the return tube mounting bolts
     
    Front muffler
     
    Sub-frame mounting bolts and the frame
     
    Transaxle front and rear mounting brackets
     
    Transaxle side mounting bolts
     

  8.  
  9. Using a suitable jack, remove the transaxle from the vehicle.
  10.  

To install:

  1. Installation is the reverse of removal keeping in mind the following torques:

    Transaxle case bolts to 15-20 ft. lbs. (20-27 Nm)
     
    Transaxle mounting sub-bracket nut 43-58 ft. lbs. (60-80 Nm)
     
    Transaxle mounting bracket bolts 29-40 ft. lbs. (40-55 Nm)
     
    Transaxle mounting insulator bolt 65-80 ft. lbs. (90-110 Nm)
     
    Clutch release cylinder retainers to 11-16 ft. lbs. (15-22 Nm)
     

  2.  
  3. Fill the transaxle to the correct level.
  4.  
  5. Start the engine and check for leaks.
  6.  
  7. Check the wheel alignment and adjust as necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle.
  4.  
  5. Remove the battery and tray.
  6.  
  7. Remove the air cleaner duct.
  8.  
  9. Remove the air cleaner and air flow hose.
  10.  
  11. Disconnect the back-up light connector, Crankshaft Position (CKP) sensor and oil pressure switch connectors.
  12.  
  13. Disconnect the speedometer cable.
  14.  
  15. Remove the clutch release cylinder bolt.
  16.  
  17. Remove the cotter pin from the shift cable at the transaxle.
  18.  
  19. Remove the clip from the shift cable on the transaxle side.
  20.  
  21. Remove the clip from the select cable at the transaxle side.
  22.  
  23. Separate the steering column shaft joint.
  24.  
  25. Separate the power steering pump hose.
  26.  
  27. Separate the hose after removing the clip from the power steering return hose.
  28.  
  29. Remove the upper transaxle bolt.
  30.  
  31. Remove the starter motor.
  32.  
  33. Install an engine support fixture.
  34.  
  35. Remove the front wheels and calipers.
  36.  
  37. Disconnect the tie rod end, wheel speed sensor, and knuckle mounting bolt.
  38.  
  39. Remove the transaxle mounting bracket and insulator.
  40.  
  41. Remove the front roll stopper insulator bolt, upper and lower stopper bolts and the front roll stopper.
  42.  
  43. Remove the rear roll stopper insulator bolt, and stopper bolt and the roll stopper.
  44.  
  45. Remove the drive shaft.
  46.  
  47. Remove the subframe bolts and subframe.
  48.  
  49. Install a transaxle jack.
  50.  
  51. Remove the transaxle lower bolts.
  52.  
  53. Remove the transaxle-to-engine bolts and the transaxle.
  54.  

To install:

  1. Installation is the reverse of removal keeping in mind the following steps and torques:
    1. Transaxle case bolts to 15-20 ft. lbs. (20-27 Nm)
    2.  
    3. Tighten the transaxle mounting bracket bolts to 43-58 ft. lbs. (60-80 Nm).
    4.  
    5. Transaxle mounting bracket bolts 29-40 ft. lbs. (40-55 Nm)
    6.  
    7. Transaxle mounting insulator bolt 65-80 ft. lbs. (90-110 Nm)
    8.  
    9. Tighten the front roll stopper-to-transaxle bolts to 43-58 ft. lbs. (60-80 Nm).
    10.  
    11. Tighten the front roll stopper insulator bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    12.  
    13. Tighten the front roll stopper-to-subframe bolts to 43-58 ft. lbs. (60-80 Nm).
    14.  
    15. Tighten the rear roll stopper-to-subframe bolts to 43-58 ft. lbs. (60-80 Nm).
    16.  
    17. Tighten the rear roll stopper-to-transaxle bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    18.  
    19. Tighten the rear roll stopper insulator bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    20.  
    21. Clutch release cylinder retainers to 11-16 ft. lbs. (15-22 Nm)
    22.  

  2.  
  3. Fill the transaxle to the correct level.
  4.  
  5. Start the engine and check for leaks.
  6.  
  7. Check the wheel alignment and adjust as necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner duct
     
    Air cleaner and air flow hose
     
    Back-up light connector
     
    Clutch line and clip
     
    Clutch release cylinder
     
    Speedometer cable
     
    Gear select or shift cables
     
    Starter motor mounting bolts
     
    Transaxle upper bolts
     

  6.  
  7. Attach an engine support fixture to the engine.

    Transaxle mounting bracket and insulator
     
    Front wheels
     
    Tie rod end, lower ball joint and drive shaft
     
    Gear box u-joint bolt and the return tube mounting bolts
     
    Front muffler
     
    Sub-frame mounting bolts and the frame
     
    Transaxle front and rear mounting brackets
     
    Transaxle side mounting bolts
     

  8.  
  9. Using a suitable jack, remove the transaxle from the vehicle.
  10.  

To install:

  1. Installation is the reverse of removal keeping in mind the following torques:

    Transaxle case bolts to 15-20 ft. lbs. (20-27 Nm)
     
    Transaxle mounting sub-bracket nut 43-58 ft. lbs. (60-80 Nm)
     
    Transaxle mounting bracket bolts 29-40 ft. lbs. (40-55 Nm)
     
    Transaxle mounting insulator bolt 65-80 ft. lbs. (90-110 Nm)
     
    Clutch release cylinder retainers to 11-16 ft. lbs. (15-22 Nm)
     

  2.  
  3. Fill the transaxle to the correct level.
  4.  
  5. Start the engine and check for leaks.
  6.  
  7. Check the wheel alignment and adjust as necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle.
  4.  
  5. Remove the battery and tray.
  6.  
  7. Remove the air cleaner duct.
  8.  
  9. Remove the air cleaner and air flow hose.
  10.  
  11. Disconnect the back-up light connector, Crankshaft Position (CKP) sensor and oil pressure switch connectors.
  12.  
  13. Disconnect the speedometer cable.
  14.  
  15. Remove the clutch release cylinder bolt.
  16.  
  17. Remove the cotter pin from the shift cable at the transaxle.
  18.  
  19. Remove the clip from the shift cable on the transaxle side.
  20.  
  21. Remove the clip from the select cable at the transaxle side.
  22.  
  23. Separate the steering column shaft joint.
  24.  
  25. Separate the power steering pump hose.
  26.  
  27. Separate the hose after removing the clip from the power steering return hose.
  28.  
  29. Remove the upper transaxle bolt.
  30.  
  31. Remove the starter motor.
  32.  
  33. Install an engine support fixture.
  34.  
  35. Remove the front wheels and calipers.
  36.  
  37. Disconnect the tie rod end, wheel speed sensor, and knuckle mounting bolt.
  38.  
  39. Remove the transaxle mounting bracket and insulator.
  40.  
  41. Remove the front roll stopper insulator bolt, upper and lower stopper bolts and the front roll stopper.
  42.  
  43. Remove the rear roll stopper insulator bolt, and stopper bolt and the roll stopper.
  44.  
  45. Remove the drive shaft.
  46.  
  47. Remove the subframe bolts and subframe.
  48.  
  49. Install a transaxle jack.
  50.  
  51. Remove the transaxle lower bolts.
  52.  
  53. Remove the transaxle-to-engine bolts and the transaxle.
  54.  

To install:

  1. Installation is the reverse of removal keeping in mind the following steps and torques:
    1. Transaxle case bolts to 15-20 ft. lbs. (20-27 Nm)
    2.  
    3. Tighten the transaxle mounting bracket bolts to 43-58 ft. lbs. (60-80 Nm).
    4.  
    5. Transaxle mounting bracket bolts 29-40 ft. lbs. (40-55 Nm)
    6.  
    7. Transaxle mounting insulator bolt 65-80 ft. lbs. (90-110 Nm)
    8.  
    9. Tighten the front roll stopper-to-transaxle bolts to 43-58 ft. lbs. (60-80 Nm).
    10.  
    11. Tighten the front roll stopper insulator bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    12.  
    13. Tighten the front roll stopper-to-subframe bolts to 43-58 ft. lbs. (60-80 Nm).
    14.  
    15. Tighten the rear roll stopper-to-subframe bolts to 43-58 ft. lbs. (60-80 Nm).
    16.  
    17. Tighten the rear roll stopper-to-transaxle bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    18.  
    19. Tighten the rear roll stopper insulator bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    20.  
    21. Clutch release cylinder retainers to 11-16 ft. lbs. (15-22 Nm)
    22.  

  2.  
  3. Fill the transaxle to the correct level.
  4.  
  5. Start the engine and check for leaks.
  6.  
  7. Check the wheel alignment and adjust as necessary.
  8.  

 
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