Automatic Transaxle: Disassembly

CAUTION: Because the automatic transaxle is composed of component parts of an especially high degree of precision, these parts should be very carefully handled during disassembly and assembly so as not to scar or scratch them.
A rubber mat should be placed on the workbench, and it should always be kept clean.
During disassembly, cloth gloves or rags should not be used. If such items must be used, use articles made of nylon, or use paper towels.
All disassembled parts must be thoroughly cleaned. Metal parts may be cleaned with ordinary detergents, but must be thoroughly air dried.
Clean the clutch disc, resin thrust plate and rubber parts by using ATF (automatic transaxle fluid), being very careful that dust, dirt, etc. do not adhere.
If the transaxle main unit is damaged, also disassemble and clean the cooler system as well.

Fig 1: Identifying Torque Converter

Courtesy of HYUNDAI MOTOR CO.

Clean away any sand, mud, etc. adhered around the transaxle.
Place the transaxle assembly on the workbench with the oil pan down.
Remove the torque converter.
Measuring input shaft end play before disassembly will usually indicate when a thrust washer change is required (except when major parts are replaced).
Standard value : 0.3-1.0 mm (0.012-0.039 in.)

Fig 2: Measuring Input Shaft End Play
Courtesy of HYUNDAI MOTOR CO.

Thrust washers are located between the reaction shaft support and rear clutch retainer, and between the reaction shaft support and front clutch retainer.

Mount a dial indicator to the converter housing with the dial indicator support.

Make sure that the indicator plunger is seated against the end of the input shaft.

When checking end play, pull out or push in the input shaft with pliers. Be careful not to scratch the input shaft. Record indicator reading for reference when reassembling the transaxle.
Remove the pulse generators "A" and "B".

Fig 3: Identifying Pulse Generators
Courtesy of HYUNDAI MOTOR CO.
Remove manual control lever, then remove the transaxle range switch.

Fig 4: Identifying Manual Control Lever & Transaxle Range Switch
Courtesy of HYUNDAI MOTOR CO.
Remove the snap ring and kickdown servo switch.

Fig 5: Identifying Torque Converter
Courtesy of HYUNDAI MOTOR CO.
Remove 6 bolts, attach the Special Tools (09452-21100) and remove oil pump assembly
NOTE:
When removing the oil pump assembly, be sure to follow to prevent the damage of onto transaxle case.
1. Turn the knob of both special service tools simultaneously and uniformly not to be inclined to "B" side.
2. While turning the special service tool, tap on the "A" side of the oil pump lightly with rubber or plastic hammer if necessary.
Fig 6: Removing Oil Pump Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove the fiber thrust washer.

Fig 7: Removing Fiber Thrust Washer
Courtesy of HYUNDAI MOTOR CO.
Pull up the input shaft, and remove the front clutch assembly and the rear clutch assembly together.

Fig 8: Removing Front/Rear Clutch Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove the thrust bearing.

Fig 9: Identifying Thrust Bearing
Courtesy of HYUNDAI MOTOR CO.
Remove the clutch hub.

Fig 10: Removing Clutch Hub
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Remove the thrust race and bearing.

Fig 11: Identifying Thrust Race & Bearing
Courtesy of HYUNDAI MOTOR CO.
Remove the kickdown drum.

Fig 12: Removing/Installing Kickdown Drum
Courtesy of HYUNDAI MOTOR CO.
Remove the kickdown band.

Fig 13: Removing Kickdown Band
Courtesy of HYUNDAI MOTOR CO.
Remove the snap ring.

Fig 14: Removing/Installing Snap Ring
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Attach the Special Tool (09453-21310) on the center support. Holding the handle of the tool, pull the center support straight upward.

Fig 15: Attaching Special Tool (09453-21310) On Center Support
Courtesy of HYUNDAI MOTOR CO.
Remove the reverse sun gear and the forward sun gear together.

Fig 16: Removing Reverse Sun Gear & Forward Sun Gear Together
Courtesy of HYUNDAI MOTOR CO.
Remove the planet carrier assembly and thrust bearing.

Fig 17: Removing Planet Carrier Assembly & Thrust Bearing
Courtesy of HYUNDAI MOTOR CO.
Remove the wave spring, return spring, reaction plate, brake disc, and brake plate.

Fig 18: Identifying Wave Spring, Return Spring, Reaction Plate, Brake Disc, & Brake Plate
Courtesy of HYUNDAI MOTOR CO.
Remove the end cover.

Fig 19: Identifying End Cover
Courtesy of HYUNDAI MOTOR CO.
Remove the end clutch assembly.

Fig 20: Removing End Clutch Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove the thrust plate.

Fig 21: Removing Thrust Plate
Courtesy of HYUNDAI MOTOR CO.
Remove the end clutch hub and thrust bearing.

Fig 22: Removing End Clutch Hub & Thrust Bearing
Courtesy of HYUNDAI MOTOR CO.
Pull out the end clutch shaft.

Fig 23: Pulling Clutch Shaft
Courtesy of HYUNDAI MOTOR CO.
Remove the oil pan and gasket.

Fig 24: Identifying Oil Pan & Gasket
Courtesy of HYUNDAI MOTOR CO.
Remove the oil filter from the valve body.

Fig 25: Removing Oil Filter
Courtesy of HYUNDAI MOTOR CO.
Remove the oil-temperature sensor installation bolt; then, after removal from the bracket, pull out from the connector.

Fig 26: Identifying Oil-Temperature Sensor
Courtesy of HYUNDAI MOTOR CO.
Remove the clip of the solenoid valve harness grommet and pull it.

Fig 27: Removing Clip Of Solenoid Valve Harness Grommet
Courtesy of HYUNDAI MOTOR CO.
Remove the 9 valve body bolts. Remove the valve body.

Fig 28: Identifying Valve Body
Courtesy of HYUNDAI MOTOR CO.
Unstake the transfer shaft lock nut stopper.

Fig 29: Unstaking Transfer Shaft Lock Nut Stopper
Courtesy of HYUNDAI MOTOR CO.
Install the Special Tool to the transaxle case.

Fig 30: Identifying Special Tool
Courtesy of HYUNDAI MOTOR CO.
Remove the locking nut.

Fig 31: Removing Locking Nut
Courtesy of HYUNDAI MOTOR CO.
Using the Special Tool, remove the transfer driven gear.

Fig 32: Removing Transfer Driven Gear
Courtesy of HYUNDAI MOTOR CO.
Remove the taper roller bearing outer race.

Fig 33: Removing Taper Roller Bearing Outer Race
Courtesy of HYUNDAI MOTOR CO.
Remove the snap ring.

Fig 34: Removing Snap Ring
Courtesy of HYUNDAI MOTOR CO.
Remove the transfer shaft and taper roller bearing.

Fig 35: Removing Transfer Shaft & Taper Roller Bearing
Courtesy of HYUNDAI MOTOR CO.
Remove the speedometer sleeve.

Fig 36: Removing Speedometer Sleeve
Courtesy of HYUNDAI MOTOR CO.
Remove the differential cover and the gasket.

Fig 37: Identifying Differential Cover
Courtesy of HYUNDAI MOTOR CO.
Before removal of the differential gear, measure the end play of the differential gear with a dial gauge.
Standard value: 0-0.15 mm (0-0.006 in.)

Fig 38: Measuring End Play Of Differential Gear
Courtesy of HYUNDAI MOTOR CO.
Remove the 5 differential bearing retainer mounting bolts.

Fig 39: Removing Differential Bearing Retainer Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Using the Special Tool, remove the differential bearing retainer.

Fig 40: Removing Differential Bearing Retainer
Courtesy of HYUNDAI MOTOR CO.
Loosen the mounting bolts and remove the bearing cap.

Fig 41: Removing Bearing Cap
Courtesy of HYUNDAI MOTOR CO.
Remove the differential assembly.

Fig 42: Removing Differential Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove two bolts of the sprag rod support and the bolt of the detent spring assembly.

Fig 43: Identifying Detent Spring Assembly & Sprag Rod Support
Courtesy of HYUNDAI MOTOR CO.
Remove the set screw, the manual control shaft assembly, the sprag rod and the detent spring assembly.

Fig 44: Identifying Manual Control Shaft Assembly, Sprag Rod, Set Screw, & Detent Spring Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove the kickdown servo snap ring.

Fig 45: Removing Kickdown Servo Snap Ring
Courtesy of HYUNDAI MOTOR CO.
Remove the kickdown piston assembly.

Fig 46: Identifying Kickdown Piston, Servo Spring, & Sleeve
Courtesy of HYUNDAI MOTOR CO.