Automatic Transaxle: Reassembly

CAUTION: Do not reuse gaskets, oil seals and rubber parts. Replace them with new ones at every reassembly. The O-ring of the oil level dipstick need not be replaced.
Do not use grease other than petrolatum or industrial vaseline. Apply automatic transaxle fluid to friction elements, rotating parts, and sliding parts before installation. Refer to LUBRICANTS . New clutch discs should be immersed in automatic transaxle fluid for a minimum of two hours before installation.
Do not apply sealer or adhesive to gaskets.
When bushings must be replaced, replace their complete assembly which.
Do not use shop towels during disassembly and reassembly operation.
The oil in the cooler should also be replaced.

After installing the detent spring assembly and the sprag rod assembly on manual control shaft, insert manual control shaft into transaxle case and push it fully toward manual control lever. At this time, do not install the O-ring (large one of two O-rings) on manual control shaft.

Fig 1: Identifying Detent Spring Assembly
Courtesy of HYUNDAI MOTOR CO.
After installing the new O-ring on manual control shaft, draw shaft back into case, then install set screw and gasket.

Fig 2: Identifying O-Ring & Set Screw
Courtesy of HYUNDAI MOTOR CO.
Install the sprag rod support and tighten two bolts. Install the washer and tighten the bolt of the detent spring assembly.
Sprag rod support bolts : 20-27 Nm (200-270 kg.cm, 15-19 lb.ft)

Detent sprag assembly bolt: 10-12 Nm (100-120 kg.cm, 7.5-8.4 lb.ft)

Fig 3: Identifying Detent Spring Assembly & Sprag Rod Support
Courtesy of HYUNDAI MOTOR CO.
Before assembly of the transaxle, measure the end play of the low-reverse brake, and select a pressure plate to be used so that the end play will be the standard value.
1. Install the brake reaction plate, brake plate and brake disc to the transaxle case.
  CAUTION: If new brake discs are used, be sure to immerse them in ATF for a minimum of two hours.
  
  Fig 4: Identifying Wave Spring, Return Spring, Reaction Plate, Brake Disc, & Brake Plate
  Courtesy of HYUNDAI MOTOR CO.
2. Install the appropriate pressure plate and then install the return spring.
  CAUTION: Be sure that the return spring is installed so that it faces in the correct direction.
  
  Fig 5: Identifying Reaction Plate & Case
  Courtesy of HYUNDAI MOTOR CO.
3. Apply a coating of petroleum jelly to the wave spring and attach it to the center support.
  
  Fig 6: Identifying Wave Spring
  Courtesy of HYUNDAI MOTOR CO.
4. Install the Special Tool (09453-21310) to the center support.
  
  Fig 7: Attaching Special Tool (09453-21310) On Center Support
  Courtesy of HYUNDAI MOTOR CO.
5. Install the snap ring.
  
  Fig 8: Identifying Snap Ring
  Courtesy of HYUNDAI MOTOR CO.
6. Install the Special Tools (09454-21400,09453-33100) and a dial gauge at the rear side of the transaxle case.
  CAUTION: Install the dial gauge so that it contacts the brake reaction plate at a right angle from the transfer idler shaft hole.
  
  Fig 9: Installing Special Tools & Dial Gauge At Rear Side Of Transaxle Case
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 10: Identifying Brake Plate, Brake Disc, & Brake Reaction Plate
  Courtesy of HYUNDAI MOTOR CO.
7. Using a manual pump, pump air (5 kg/cm² ) in from the position shown in Fig 11. Read the dial indicator gauge, and select the pressure plate that will provide the standard value.
8. After selecting pressure plate, remove center support, brake plate, brake disc, brake reaction plate and pressure plate
Fig 11: Pumping Air Using Manual Pump
Courtesy of HYUNDAI MOTOR CO.
Install the transfer shaft, and press-fit the bearing outer race to the transaxle case.

Fig 12: Installing Transfer Shaft
Courtesy of HYUNDAI MOTOR CO.
Install the transfer shaft snap ring.

Fig 13: Installing Transfer Shaft Snap Ring
Courtesy of HYUNDAI MOTOR CO.
Insert the spacer on the transfer shaft.

Fig 14: Installing Spacer On Transfer Shaft
Courtesy of HYUNDAI MOTOR CO.
Install the bearing cage on the case.

Fig 15: Installing Bearing Cage On Case
Courtesy of HYUNDAI MOTOR CO.
Press-fit the transfer driven gear to the transfer shaft.

Fig 16: Pressing Transfer Driven Gear To Transfer Shaft
Courtesy of HYUNDAI MOTOR CO.
Tighten the lock nut to the specified torque.
Transfer lock nut:

200-230 Nm (2000-2300 kg.cm, 146-166 lb.ft)

Fig 17: Tightening Lock Nut
Courtesy of HYUNDAI MOTOR CO.
After installing the dial gauge, measure the end play of the transfer shaft: then select the spacer (s) needed to obtain the standard value, and refit.
Transfer shaft end play: 0-0.06 mm (0-0.002 in.)

Fig 18: Measuring End Play Of Transfer Shaft
Courtesy of HYUNDAI MOTOR CO.
Using a punch, lock the lock nut to prevent rotation.

Fig 19: Locking Lock Nut Using Punch
Courtesy of HYUNDAI MOTOR CO.
Install the transfer drive gear assembly.

Fig 20: Identifying Transfer Drive Gear Assembly
Courtesy of HYUNDAI MOTOR CO.
Install the Special Tool at the rear side of the transaxle case.

Fig 21: Installing Special Tool Rear Side Of Transaxle Case
Courtesy of HYUNDAI MOTOR CO.
Using the Special Tool, insert an assembly of the annulus gear into the transfer drive gear.

Fig 22: Inserting Assembly Of Annulus Gear Into Transfer Drive Gear
Courtesy of HYUNDAI MOTOR CO.
Install the stopper plate and snap ring.

Fig 23: Identifying Stopper Plate & Snap Ring
Courtesy of HYUNDAI MOTOR CO.
Apply specified sealant to the rear cover.
Specified sealant: THREE BOND 1281B

Fig 24: Applying Specified Sealant To Rear Cover
Courtesy of HYUNDAI MOTOR CO.
Install the rear cover assembly.
Tightening torque:

17-22 Nm (170-220 kg.cm, 12.3-15.9 lb.ft)

Fig 25: Installing Rear Cover Assembly
Courtesy of HYUNDAI MOTOR CO.

Install snap ring.

Fig 26: Installing Snap Ring

Courtesy of HYUNDAI MOTOR CO.

Fig 27: Identifying Thrust Bearings, Thrust Races, & Thrust Washers

Courtesy of HYUNDAI MOTOR CO.

Identification of thrust bearings, thrust races and thrust washers

THRUST BEARING/RACE/WASHER THICKNESS & INNER/OUTER DIAMETER REFERENCE CHART

Unit: mm (in.)
Outer diameter	Inner diameter	Thickness	Code No.
70 (2.756)	55.7 (2.193)	1.4 (0.055)	#1
70 (2.756)	55.7 (2.193)	1.8 (0.071)
70 (2.756)	55.7 (2.193)	2.2 (0.087)
70 (2.756)	55.7 (2.193)	2.6 (0.102)
70 (2.756)	55.7 (2.193)	1.8 (0.071)	#2
48.9 (1.925)	37 (1.457)	1.0 (0.039)	#3
48.9 (1.925)	37 (1.457)	1.2 (0.047)
48.9 (1.925)	37 (1.457)	1.4 (0.055)
48.9 (1.925)	37 (1.457)	1.6 (0.063)
48.9 (1.925)	37 (1.457)	1.8 (0.071)
48.9 (1.925)	37 (1.457)	2.0 (0.079)
48.9 (1.925)	37 (1.457)	2.2 (0.087)
48.9 (1.925)	37 (1.457)	2.4 (0.094)
48.1 (1.906)	34.4 (1.354)	-	#4
40 (1.575)	21 (0.827)	2.4 (0.094)	#5
42.6 (1.677)	28 (1.102)	-	#6
54 (2.126)	38.7 (1.524)	1.6 (0.063)	#7
52 (2.047)	36.4 (1.433)	-	#8
41 (1.614)	28 (1.102)	-	#9
39 (1.535)	28 (1.102)	1.2 (0.047)	#10
38 (1.496)	22.2 (0.874)	-	#11
52 (2.047)	36.4 (1.433)	-	#12
58 (2.283)	44 (1.732)	-	#13

Apply a coating of petroleum jelly to thrust bearing #12 and attach to the planetary carrier.

Fig 28: Identifying Thrust Bearing
Courtesy of HYUNDAI MOTOR CO.
Install the planetary carrier to the case.

Fig 29: Installing Planetary Carrier To Case
Courtesy of HYUNDAI MOTOR CO.
Assemble the reverse sun gear and the forward sun gear in the following order:
1. Attach the seal ring and the snap ring to the reverse sun gear. When attaching, squeeze the seal ring as shown in Fig 30.
2. Attach thrust race #10 to the forward sun gear.
3. Attach thrust bearing #9 to the forward sun gear.
  
  Fig 30: Squeezing Seal Ring
  Courtesy of HYUNDAI MOTOR CO.
4. Assemble the reverse sun gear, and then the forward sun gear.
Fig 31: Assembling Reverse Sun Gear & Forward Sun Gear
Courtesy of HYUNDAI MOTOR CO.
Install both of the previously assembled sun gears into the planetary carrier.

Fig 32: Installing Both Of Previously Assembled Sun Gears Into Planetary Carrier
Courtesy of HYUNDAI MOTOR CO.
Install the brake disc and brake plate.

Fig 33: Installing Brake Disc & Brake Plate
Courtesy of HYUNDAI MOTOR CO.
Install the selected brake pressure plate.

Fig 34: Installing Selected Brake Pressure Plate
Courtesy of HYUNDAI MOTOR CO.
Install the return spring. (Spring type)

Fig 35: Installing Return Spring
Courtesy of HYUNDAI MOTOR CO.
Apply a coating of petroleum jelly to the wave spring and attach it to the center support.

Fig 36: Identifying Wave Spring
Courtesy of HYUNDAI MOTOR CO.
Install the two new O-rings to the center support.

Fig 37: Identifying O-Rings
Courtesy of HYUNDAI MOTOR CO.
After applying a coating of ATF to the O-rings, install the special tool (09453-21310) to the center support, and install into the case.
CAUTION: Be sure that the wave spring is not out of position

Fig 38: Identifying Special Tool (09453-21310) To Center Support
Courtesy of HYUNDAI MOTOR CO.
Install the snap ring.

Fig 39: Removing/Installing Snap Ring
Courtesy of HYUNDAI MOTOR CO.
Assemble a new seal ring (large diameter) and D-ring (small diameter) to the kickdown servo piston, and install a new O-ring in the groove around the sleeve; then assemble the kickdown servo spring, piston and sleeve in the transaxle case.

Fig 40: Identifying Kickdown Piston, Servo Spring, & Sleeve
Courtesy of HYUNDAI MOTOR CO.
Press the kickdown servo and sleeve, and install the snap ring.

Fig 41: Installing Snap Ring
Courtesy of HYUNDAI MOTOR CO.
Install the end clutch shaft. Be sure to install the longer spline toward the front as shown.

Fig 42: Installing Clutch Shaft
Courtesy of HYUNDAI MOTOR CO.
Fit the thrust washer toward the return spring at the end clutch side.

Fig 43: Installing Thrust Washer
Courtesy of HYUNDAI MOTOR CO.
Install the end clutch hub to end clutch.

Fig 44: Installing End Clutch Hub To End Clutch
Courtesy of HYUNDAI MOTOR CO.
Attach, using petroleum, thrust bearing #13 to the end clutch hub.

Fig 45: Attaching Thrust Bearing To End Clutch Hub
Courtesy of HYUNDAI MOTOR CO.
Install the end clutch assembly.

Fig 46: Installing End Clutch Assembly
Courtesy of HYUNDAI MOTOR CO.
Attach a new O-ring and D-ring to the end clutch cover.
CAUTION: Install so that the D-ring is not twisted.
Apply a sufficient amount of automatic transaxle fluid to the bearing.

Fig 47: Identifying Clutch Cover
Courtesy of HYUNDAI MOTOR CO.
Attach the end cover and fasten it with four bolts.
CAUTION: When installing the end cover, be sure the screw hole is correctly aligned. If the end cover is turned (after it is installed) in order to align with the screw hole, the O-ring and/or the D-ring may be twisted as result.

Fig 48: Identifying End Cover
Courtesy of HYUNDAI MOTOR CO.
Install kickdown drum with its splines in mesh with the sun gear. Place the kickdown band on the kickdown drum and tighten the kickdown servo adjusting screw to keep the band in position.

Fig 49: Removing/Installing Kickdown Drum
Courtesy of HYUNDAI MOTOR CO.
Apply a coating of petroleum jelly to thrust bearing #8, and then attach to the kickdown drum.

Fig 50: Identifying Thrust Bearing
Courtesy of HYUNDAI MOTOR CO.
Apply a coating of petroleum jelly to thrust race #7, and then attach to the rear clutch hub.

Fig 51: Identifying Thrust Race
Courtesy of HYUNDAI MOTOR CO.
Install the clutch hub to the sun gear splines.

Fig 52: Installing Clutch Hub To Sun Gear Splines
Courtesy of HYUNDAI MOTOR CO.
Attach thrust bearing #6 onto the hub using petroleum jelly.

Fig 53: Attaching Thrust Bearing Onto Hub
Courtesy of HYUNDAI MOTOR CO.
Apply a coating of petroleum jelly to thrust washer #2 and thrust bearing #4. Attach to the rear clutch assembly.

Fig 54: Identifying Thrust Bearing & Thrust Washer
Courtesy of HYUNDAI MOTOR CO.
Combine the rear clutch and the front clutch assemblies.

Fig 55: Identifying Rear Clutch & Front Clutch Assemblies
Courtesy of HYUNDAI MOTOR CO.
Install the end clutch assembly.

Fig 56: Removing Front/Rear Clutch Assembly
Courtesy of HYUNDAI MOTOR CO.

If end play which was measured and recorded at disassembly is not within standard value, adjust to specification by selecting thrust race #3.

Standard value: 0.3-1.0 mm (0.012-0.040 in.)

When the thrust race is replaced with that of a different thickness, also replace thrust washer#1 located between the oil pump and front clutch. Use a washer of proper corresponding thickness corresponding to thrust race.

Find correct pair of thrust races (metal) and thrust washers (fiber) from following table.

THRUST WASHER #1 & THRUST RACE #3 THICKNESS SPECIFICATIONS

Thrust washer #1 (fiber)	Thrust race #3 (metal)
Thickness mm (in.)	Thickness mm (in.)
1.4 (0.055)	1.0 (0.039)
1.4 (0.055)	1.2 (0.047)
1.8 (0.071)	1.4 (0.055)
1.8 (0.071)	1.6 (0.063)
2.2 (0.087)	1.8 (0.071)
2.2 (0.087)	2.0 (0.079)
2.6 (0.102)	2.2 (0.087)
2.6 (0.102)	2.4 (0.095)

Example:

When a different thickness thick thrust race is selected, a corresponding thrust washer must be paired with it.

Attach the reused thrust washer #1, or the one selected in step 48 to the front clutch by using petroleum jelly.
Install the Special Tool (09452-21401) to the case.

Fig 57: Installing Special Tool (09452-21401) To Case
Courtesy of HYUNDAI MOTOR CO.
Attach the reused thrust race #3 or the one selected in step 50 to the oil pump by using petroleum jelly.

Fig 58: Installing Thrust Race
Courtesy of HYUNDAI MOTOR CO.
Install a new oil pump gasket and the oil pump assembly.

Fig 59: Identifying Oil Pump Assembly
Courtesy of HYUNDAI MOTOR CO.
Install a new O-ring in the groove of the oil pump housing and lightly apply automatic transaxle fluid to the outside surface of the O-ring.
Install the oil pump assembly by tightening the six bolts evenly. When installing this oil pump assembly, be careful that the thrust washer remains in place.

Fig 60: Identifying Oil Pump Assembly
Courtesy of HYUNDAI MOTOR CO.
Check the input shaft end play. Readjust if necessary (see step 50).
Standard value: 0.3-1.0 mm (0.012-0.040 in.)

Fig 61: Checking Input Shaft End Play
Courtesy of HYUNDAI MOTOR CO.
Install the O-ring at the center of the top of the valve body assembly (brake oil pressure passage).
Install the valve body assembly to the case, fitting the detent plate (manual control shaft) pin in the slot of the manual valve.

Fig 62: Identifying Valve Body Assembly
Courtesy of HYUNDAI MOTOR CO.
Replace the O-ring of the solenoid valve connector with a new one.
Tighten the valve body assembly mounting bolts to 10-12 Nm (100-120 kg.cm, 7-9 lb.ft)
Install the oil filter. Tighten the four oil filter mounting bolts to 5-7 Nm (50-70 kg.cm, 4-5 lb.ft)

Fig 63: Identifying Oil Filter Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Install five magnets into the five depression provided in the oil pan.

Fig 64: Identifying Magnets
Courtesy of HYUNDAI MOTOR CO.
Install a new oil pan gasket and oil pan. Tightening 12 bolts to 10-12 Nm (100-120 kg.cm, 7-9 lb.ft)

Fig 65: Identifying Oil Pan
Courtesy of HYUNDAI MOTOR CO.
Install a new D-ring to the kickdown servo switch. Press into the case and secure using the proper snap ring.

Fig 66: Installing D-Ring
Courtesy of HYUNDAI MOTOR CO.
Install the transaxle range switch and manual lever. Adjust the transaxle range switch.

Fig 67: Identifying Transaxle Range Switch & Manual Lever
Courtesy of HYUNDAI MOTOR CO.
Install the pulse generator.

Fig 68: Identifying Pulse Generator
Courtesy of HYUNDAI MOTOR CO.
Install the differential assembly.

Fig 69: Identifying Differential Assembly
Courtesy of HYUNDAI MOTOR CO.
Place two pieces of solder, roughly 10 mm (0.4 in.) long and 3 mm (0.12 in.) in diameter, at the position shown on the differential bearing retainer outer race.

Fig 70: Identifying Solder Area On Differential Bearing Retainer Outer Race
Courtesy of HYUNDAI MOTOR CO.
Install the differential bearing retainer and tighten the bolt to specified torque.
Standard value : 43-55 Nm (430-550 kg.cm, 31-40 lb.ft)

Fig 71: Identifying Differential Bearing Retainer
Courtesy of HYUNDAI MOTOR CO.
Remove the differential bearing retainer
Remove the crushed solder from the outer race of the differential bearing.
Using a micrometer, measure the thickness of the crushed solder.
Select and install a spacer so that the preload of the differential bearing will be the standard value.

Standard : 0-0.15 mm (0-0.006 in.)

Fig 72: Measuring Thickness Of Crushed Solder
Courtesy of HYUNDAI MOTOR CO.
Apply the ATF to the new installed O-ring and install the differential bearing retainer.

Fig 73: Identifying O-Ring
Courtesy of HYUNDAI MOTOR CO.
Install the differential bearing cap.
Tightening torque

Standard value: 60-80 Nm (600-800 kg.cm, 43-58 lb.ft)

Fig 74: Identifying Differential Bearing Cap
Courtesy of HYUNDAI MOTOR CO.
Install the speedometer sleeve.
Tightening torque

Standard value: 10-12 Nm (100-120 kg.cm, 7-9 lb.ft)

Fig 75: Installing Speedometer Sleeve
Courtesy of HYUNDAI MOTOR CO.
Install the differential cover and the rear roll bracket with new gasket.

Fig 76: Identifying Differential Cover
Courtesy of HYUNDAI MOTOR CO.
After applying automatic transaxle fluid to the outside surface of the oil pump-side cylindrical portion of the torque converter, install the torque converter carefully so as not to damage the seal lip. Make certain that the torque converter is in mesh with oil pump drive gear.
Measure the distance between the ring gear end and the converter housing end. The torque converter has been properly installed when measurement is approximately 12 mm (0.47 in.)

Fig 77: Identifying Torque Converter
Courtesy of HYUNDAI MOTOR CO.