M/T - Removal Procedures

Group: TRANSAXLE

Number: 96-40-025

Date: NOVEMBER, 1996

Model: 1996-1997 Elantra
1997 Tiburon

Subject
TRANSAXLE R & R PROCEDURES FOR VEHICLES EQUIPPED WITH "PULL" STYLE CLUTCH RELEASE BEARING (SHOP MANUAL ADDITION)

This bulletin provides information additional to the shop manual procedures.

DESCRIPTION:

Beginning with the 1996 model year Elantra and 1997 model year Tiburon, these models are equipped with a new style manual transaxle, (model # M5BF1). This transaxle utilizes a "pull" rather than "push" style clutch release mechanism. When removal of the transaxle and/or clutch becomes necessary, the following procedures must be followed to prevent damage to the components.

SERVICE PROCEDURES:

Before beginning the transaxle removal process, make certain that you have the proper engine support fixture; P/N 09400-29000 or its equivalent.

1. Follow the transaxle removal procedures found in the appropriate shop manual, beginning on page(s); 1996 Elantra, page MT-19; 1997 Elantra and Tiburon, page MT-15.





2. In step 10, the "engine hoist" refers to the engine support fixture illustrated.





Between steps 21 and 22, add the following procedures:

3. Remove clutch release lever nut & washer.

4. Remove clutch release spring clip and clevis pin.

5. Remove clutch release lever & cylinder.

6. When the transaxle is removed, the clutch release bearing will remain attached to the clutch cover. Removal of the clutch release bearing must be done before the clutch cover is removed from the flywheel.

7. Using snap ring pliers, spread the snap ring on the clutch release bearing while pushing the bearing into the clutch cover.

8. With the pliers still in place, use a prybar to separate the clutch release bearing from the clutch cover.

Installation:

Note:
Apply multipurpose grease to the bearing sleeve and release fork contact points.

9. Place clutch release bearing onto transaxle/clutch release fork.

10. Install transaxle.

11. With all of the bolts installed around the bell housing, install the clutch release lever. Push the clutch release lever in its normal direction of travel until a "click" is heard (this "clicking" sound is the snap ring seating to the bearing).





Note:
There should be no more than 3° of free travel at clutch release lever after bearing is seated to clutch cover.

12. Complete installation as directed by shop manual.