Removal and installation of a manual gearbox (Hyundai Santa Fe CM)

Removal

Disconnect the cable from the negative (–) battery terminal.

Remove the air filter duct.

Remove the air cleaner assembly and engine air intake duct.

Disconnect the reverse light switch connector.

Disconnect the clutch hydraulic tubes and their clamps.

Fig. 3.5. Clutch hydraulic drive slave cylinder

Remove the clutch hydraulic drive slave cylinder (Fig. 3.5).

Disconnect the speedometer drive cable.

Fig. 3.6. Removing the gear shift cable

[The material was obtained from a web resource: HyundaiBook.ru]

Remove the gear shift cable and gear selector cable (Fig. 3.6).

Remove the starter mounting bolts and remove the upper transmission connecting bolts.

Secure the engine to a special device (crossbar 09200-38001) using the mounting brackets.

Remove the transmission mount bracket and transmission mount.

Raise the car on a lift.

Remove the front wheels.

Remove the drain plug and drain the oil from the gearbox.

Disconnect the tie rod ends, lower arm ball joints and wheel drive shafts.

Loosen the bolt and disconnect the cardan joint of the steering shaft, then loosen the bolts securing the steering gear return pipe.

Remove the front muffler.

Remove the subframe mounting bolts and the subframe.

Remove the front and rear transmission mounting brackets.

Fig. 3.7. Gearbox side mounting bolts

Remove the side gearbox mounting bolts (Fig. 3.7).

Lower the transmission assembly out of the engine compartment, supporting it with a hydraulic jack.

Note: When supporting the transmission assembly, ensure that the hydraulic trolley jack support acts over a large area of the transmission case and that the jack force is not applied to one local point on the transmission case.

Caution: Engine and gearbox mounts must be installed in the order listed below.

Attention! Side engine support bracket.

Attention! Gearbox support bracket.

Attention! Rear engine mount bracket.

Attention! Front engine mount bracket.

Caution! Be careful when installing the front engine mount bracket, do not damage or deform the support. If the support is damaged, strong vibration of the power unit may occur when the engine is idling.