Manual gearbox — disassembly and installation (Hyundai Sonata Y3)

Disassembly

1. Remove the back cover bolts and remove the back cover.

2. Remove the tail light switch, gasket and mounting bracket.

3. Remove the poppet valve plugs, springs and balls.

4. Remove the speedometer drive gear assembly.

5. Remove the spring font using a special tool (09414-11000).

6. Remove the shaft nuts.

1) Unscrew the nuts of the drive and intermediate shafts.
2) Shift the transmission into reverse using the control lever and selector lever.
3) Install the special tool (09432-21101) on the drive shaft.
4) Screw a 10mm diameter bolt into the hole on the clutch housing and attach the handle to the special tool.
5) Remove the nut using the bolt as a stop.

7. Remove the fifth gear synchronizer sleeve and its shift fork.

8. Remove the fifth gear synchronizer hub, synchronizer ring, fifth gear gear and needle bearing.

9. Remove the intermediate gear using a special tool (09455-21000).

10. Remove the reverse gear shaft bolt and stop ball assembly.

11. Remove the transmission cover and housing bolts in the block with the drive axle.

12. Remove the differential oil seal and oil guide.

13. Remove the driven shaft bearing outer ring and spacer ring using the special tool (09455-32200).

14. Remove the intermediate shaft bearing outer race and spacer ring.

15. Remove the differential bearing outer race and spacer ring.

16. Remove the reverse shift lever and reverse shift shoe.

17. Remove the reverse gear shaft and remove the gear.

18. Remove the spring pins using a special tool (09414-11000).

19. Disconnect the shift guide and fork assembly.

1) Shift the shift fork from the first to the second gear to the second gear.
2) Shift the shift fork from third to fourth wheel.
3) Remove the shift guide assembly.

20. Remove the bearing retainer.

21. Lift the drive shaft assembly and remove the intermediate shaft assembly.

22. Remove the driven shaft assembly and the differential gear assembly.

23. Remove the outer race of the drive shaft bearing and the spacer ring using the special tool (09455-32200).

24. Remove the driven shaft bearing outer race and spacer ring using the same special tool (09455-3220)

25. Remove the differential bearing oil seal.

26. Remove the drive shaft oil seal.

Installation.

1. Install the drive shaft oil seal using the special tool (09431-21200).

2. Install the drive shaft seal using a special tool (09431-21000).

3. Install the differential gear bearing spacer ring.

4. Install the driven shaft bearing outer ring and spacer ring using the special tool (09500-11000, 09532-11500).

5. Install the oil guide, as well as the outer ring of the intermediate shaft bearing and the spacer ring, using the special tool (09500-21000, 09432-33400).

6. Install the differential gear assembly and the driven shaft assembly.

7. When lifting the drive shaft assembly, install the intermediate shaft assembly at the same time.

8. Install the bearing retainer.

9. Assemble the shift guide assembly:

1) Install the first to second gear shift sleeve.
2) Install the third to fourth gear shift sleeve.
3) Install the first to second gear shift guide assembly and the shift fork assembly with the selector lever pulled toward the fifth reverse gear shift guide side.
4) Install the 3rd to 4th/5th gear-reverse shift guide assembly and shift forks together with the selector lever fully pressed against the 1st to 2nd gear guide side.
5) Install the 3rd to 4th/Reverse shift guide assembly and shift fork assembly.

10. Assemble the spring pin.

1) Install the spring pins using a special tool (09414-11100).
2) When installing, make sure that the slot of the spring pin matches the center line of the guide.

Warning: Do not reuse used spring pins.

11. Install the reverse gear lever assembly.

12. Install the reversing gear shaft and the gear itself in the direction shown in the figure.

13. Install the reverse shift lever and shoe.

14. Install the intermediate shaft bearing outer race and spacer ring into the transmission housing using the special tool (09500-21060, 09432-33400).

15. Install the output shaft bearing outer race and spacer ring to the transmission housing using the special tool (09500-11000, 09532-11500).

16. Install the differential bearing spacer ring into the transmission housing.

17. Install the input shaft oil seal in the transmission housing using the special tool (09431-21200).

18. Assemble the spacer ring (to adjust axial runout).

1) Place two pieces of solder approximately 10mm long and 3mm in diameter on the bearing outer ring as shown in the figure and install the outer ring in place.
2) Install the transmission housing and tighten the bolts to the specified torque.
3) Remove the transmission housing.
4) Remove the outer ring and solder.
5) Measure the thickness of the crushed solder with a micrometer, select and install a spacer ring of such thickness that provides a standard value of axial runout.

5) Measure the thickness of the crushed…

Standard size:

Axial runout of intermediate shaft: 0.05-0.10 mm
Axial runout of output shaft: 0.05-0.10 mm
Axial runout of differential housing: 0.05-0.10 mm

19. Install the oil guide on the transmission housing.

20. Apply the recommended sealing compound to the transmission housing joint (1-2 mm).

Recommended sealant: Tri Bond 1216

21. Install the transmission housing by bolting it to the clutch housing.

22. Install the limit ball and gasket.

23. Center the shaft using a Phillips screwdriver.

24. Tighten the idler reversing gear shaft bolt to the specified tightening torque.

25. Install the balls, springs and valve plugs.

26. Install the tail light assembly.

27. Install the intermediate gear using a special tool (09432-33300).

28. Install the fifth gear wheel, synchronizer ring, needle bearing, and synchronizer hub.

29. Install the fifth gear shift fork and the synchronizer sleeve at the same time.

30. When installing the spring pin, use a special tool (09414-11100).

31. Make sure that the slot of the spring pin is in line with the center line of the guide.

Warning: Do not reuse spring pins.

32. Assemble the lock nuts.

1) Install the special tool (09432-21101) on the drive shaft.
2) Screw the bolt (10mm diameter) into the hole in the surface of the clutch housing and attach the handle to the special tool (09432-21101).
3) Shift the transmission into reverse using the control lever and selector lever.
4) Tighten the nut to the required tightening torque.