Gearbox since 2000 — disassembly and assembly (Hyundai Elantra J1)

Disassembly

Disconnect the gear shift cable bracket.





After unscrewing the mounting bolts, remove the rear gearbox cover (arrow).





Remove the reverse light switch, gasket and bracket.

After unscrewing the plugs, remove the springs and balls.



Remove the breather.

Remove the pin using a punch.



Remove the cotter pins from the primary and intermediate shaft lock nuts.



Turn the gear shift and selector levers to engage 1st gear.





After moving the fifth gear synchronizer towards the gear, loosen the lock nuts.

Remove the 5th gear shift fork with the sleeve.



Using the tool, remove the 5th gear synchronizer hub and gear wheel with needle bearing.

Using the tool, remove the 5th gear idler gear.



Remove the bushing and retaining ring (using a screwdriver).





Loosen the reverse gear axle bolt.



After unscrewing the bolts (arrow), disconnect the main gear housing from the clutch housing.



Remove the oil pans from the crankcase.



Using a special tool, remove the outer bearing ring. Remove the bushing.





Remove the shift lever.



Remove the reverse gear pinion with the axle.

Remove the pins using a punch.



Remove the rods and shift forks.



Remove the bearing separator.





Lift the input shaft assembly and remove the intermediate shaft assembly (simultaneously).



Remove the differential drive gear assembly.



After unscrewing the bolt, remove the speedometer drive gear.



Using a special tool, remove the outer ring of the secondary shaft bearing.





Using suitable tools, remove the input shaft and intermediate shaft oil seals.







Remove the secondary shaft oil pan.



Using a suitable tool, remove the input shaft seal from the crankcase.



Remove the control shaft from the crankcase.



Clean and wash the removed gearbox components.

Assembly

The gearbox is assembled in the reverse order.