Synchronizer bushing and hub (Hyundai Sonata Y3)

1. Assemble the synchronizer sleeve and its hub and check the smoothness of their movement.

2. Check the bushing for damage at its inner, front and rear ends.

3. Check the wear of the end surfaces of the hub.

Replace the synchronizer sleeve and hub as a set.

Crackers and synchronizer spring

(The material is reprinted from another resource: «www.hyundaibook.ru»)

1. Check if the central projection of the synchronizer key is worn.

2. Check that the spring is not weakened, deformed or damaged.

Transmissions

1. Check the bevel gear and clutch gear teeth for damage and wear.

2. Check whether the surface of the synchronizer cone is rough, damaged or worn.

3. Check the gear bore and front and rear ends for damage and wear.

Assembly

1. Install the hub and synchronizer sleeve so that they are positioned as shown in the figure.



2. The synchronizer sleeve has teeth that are interrupted in six places.

Assemble this sleeve with the hub so that the central tooth located between the two teeth where there is a gap touches the synchronizer key.





3. Install the synchronizer spring so that its protrusion can enter the groove in the synchronizer crackers.

When installing the synchronizer springs, make sure that the front and rear springs are not facing in the same direction.



4. Install the needle bearing and third speed gear onto the input shaft.

5. Install the third-fourth speed synchronizer assembly onto the input shaft using the special tool (09432-33300).

Warning:

• 1. When installing the synchronizer unit, make sure that the three synchronizer crackers are properly installed in the corresponding grooves of the synchronizer ring.
• 2. After installing the synchronizer unit, check whether the third gear gear rotates smoothly.

6. Install the needle bearing using the same special tool (09432-33300).



7. Install the synchronizer ring, needle bearing, fourth speed gear and spacer ring.

8. Install the snap ring.

9. Install the rear bearing using the special tool (09432-33300).

10. Install the clamping ring.

11. Install the rear bearing bushing using the special tool (09432-33300).

12. Install the front bearing using the special tool (09432-33300).