Gearbox control mechanism — removal, installation, testing and adjustment (Hyundai Sonata EF)

Removal

1. Remove the center console trim elements (see chapter "Body").



2. Unscrew the nut and remove the washer.





3. Remove the automatic transmission control cable retainer.



4. Loosen the gearbox control mechanism bolts and disconnect the connector.

5. Remove the gearbox control mechanism.

6. Loosen the selector handle screws and remove the handle.



7. Remove the automatic transmission selector position indicator.



8. Remove the retainer and unscrew the automatic transmission control cable nut.





9. Remove the automatic transmission control cable.

10. Remove the automatic transmission selector lock cables and the ignition key.

Installation

The gearbox control mechanism is installed in the reverse order of removal; the tightening torques for the bolts and nuts are indicated in the assembly drawing "Gearbox control mechanism".

Adjusting the automatic transmission selector lock cables and the ignition key (models before 2001)

1. Move the selector from position "N" to position "P".



2. Make sure the cams are in the position shown in the figure.





3. Install the selector lock cable and the ignition key lock cable as shown in the figure. The other end of the ignition key lock cable should be fixed in the ignition switch, and the selector lock cable should be on the brake pedal in the appropriate position.



4. Temporarily connect both cables to the automatic transmission selector lever as shown in the figure. Securely fasten each cable to the pin of the corresponding cam.

5. Lightly press the lever in the "D" direction and lock the automatic transmission selector lock cam.

6. Pull the selector lever lock cable slightly in direction "E". Make sure that the automatic transmission selector lock cam does not move.

7. Make sure that the end of the selector lever lock cable touches the pin of the automatic transmission selector lock cam, then secure the outer sheath of the cable with a nut and the inner sheath with a washer and cotter pin.

8. Lightly press the key lock cam in the ignition switch in the "O" direction.

9. Pull the ignition key interlock cable slightly in the "G" direction to tighten the cable, and then secure the outer sheath of the cable with the nut.



10. Press the lever in the direction of the automatic transmission selector lock cam pin and secure the inner braid with a cotter pin. Make sure that the automatic transmission selector lock cam is motionless.



11. Check that the ignition key lock cable end and the selector lever lock cable are secure.

Checking the operation of the automatic transmission selector lock system and the key in the ignition switch (models before 2001)

1. After making sure that the automatic transmission selector is set to the "P" position and the brake pedal is not pressed, check that it is impossible to press the lock button on the selector and move the selector to any other position.

2. After making sure that the key in the ignition switch is in any position except "LOCK" (for example, "ACC"), the brake pedal is pressed (travel 32 + 5 mm) and the automatic transmission selector is set to the "P" position, check the ability to press the lock button on the selector and smoothly move the selector to any other position.

3. By pressing the brake pedal, make sure that the automatic transmission selector can be smoothly moved to the "P" position from any other position.



4. Make sure the brake pedal moves smoothly.

5. With the ignition key in the "LOCK" position and the brake pedal pressed, check that the lock button on the selector cannot be pressed.

6. Make sure that it is impossible to turn the key in the ignition switch to the "LOCK" position when the automatic transmission selector lever is set to a position other than "P".

7. After moving the automatic transmission selector to the "P" position, make sure that the key in the ignition switch can be smoothly turned to the "LOCK" position.

Checking the automatic transmission selector lock cams and the key in the ignition switch (models since 2001)

1. Move the automatic transmission selector lever to the "P" position and set the locking cam of the ignition key as shown in the figure.



2. Make sure that the ignition key lock cam is in position "B" and is held by the stop pin.



3. Make sure that the automatic transmission selector lever lock cam is in position "A".



4. Make sure the ignition key is in the "LOCK" position.

Adjusting the selector lever lock cable and ignition key lock cable (models from 2001)

1. Make sure the cams are in the position shown in the figure.

2. Install the selector lock cable and the ignition key lock cable as shown in the figure. The other end of the ignition key lock cable should be fixed in the ignition switch, and the selector lock cable should be on the brake pedal in the appropriate position.

3. Temporarily connect both cables to the automatic transmission selector lever as shown in the figure. Securely fasten each cable to the pin of the corresponding cam.

4. Pull the selector lever lock cable slightly in direction "E". Make sure that the automatic transmission selector lock cam does not move.



5. Make sure that the tip of the selector lever lock cable contacts the pin of the automatic transmission selector lock cam, then fix the outer sheath of the cable to the bracket using a self-tapping bolt.

6. Lightly press the key lock cam in the ignition switch in the "Q" direction.

7. Pull the ignition key interlock cable slightly in the "G" direction to tighten the cable, and then secure the outer sheath of the cable with the nut.



8. Check that the ignition key lock cable end and the selector lever lock cable are secure.

Checking the operation of the automatic transmission selector lock system and the key in the ignition switch (models since 2001)

1. After making sure that the automatic transmission selector is set to the "P" position and the brake pedal is not pressed, check that it is impossible to press the lock button on the selector and move the selector to any other position.

2. After making sure that the brake pedal is pressed (15-22 mm travel) and the automatic transmission selector is set to the "P" position, check the ability to press the lock button on the selector and smoothly move the selector to any other position.

3. By pressing the brake pedal, make sure that the automatic transmission selector can be smoothly moved to the "P" position from any other position.

4. Make sure the brake pedal moves smoothly.

5. With the ignition key in the "LOCK" position, check that the lock button on the selector can be pressed, regardless of the position of the brake pedal.

6. Make sure that it is impossible to turn the key in the ignition switch to the "LOCK" position when the automatic transmission selector lever is set to a position other than "P".

7. After moving the automatic transmission selector to the "P" position, make sure that the key in the ignition switch can be smoothly turned to the "LOCK" position.