M/T - Transaxle Removal and Installation

Group
40 - TRANSAXLE

Number
03-40-011

Date
06-2003

Model
ELANTRA 1996-2003, SANTA
FE 2001-2003, SONATA 1996-2003
AND TIBURON 1997-2003

Subject
TRANSAXLE REMOVAL AND INSTALLATION
SERVICE PROCEDURE FOR THE PULL TYPE
CLUTCH SYSTEM

DESCRIPTION:

This bulletin provides a service procedure for the removal and installation of manual transaxles with the "pull" type clutch system.

"Pull" or "push" type clutch systems refer to the direction of operation to disengage the clutch relative to the flywheel. In a "pull" type clutch system, the release bearing is attached to the clutch cover fingers and "pulls" the clutch cover away from the clutch disc (away from the flywheel), disengaging the clutch.

VEHICLES AFFECTED:

All 1996 Model Year and newer vehicles equipped with manual transaxles except Accents which have the "push" type clutch system.

SERVICE PROCEDURE:

1. Drain the transaxle gear oil.





2. The reference photo shows the clutch related components as viewed from outside the transaxle case.





3. Loosen the release lever nut and washer.





4. Separate the release lever by removing the snap pin and clevis pin.





5. Separate the release lever from the fork shaft.





6. Loosen the bolts attached to the release cylinder and separate the release cylinder from the transaxle assembly (no need to open the clutch hydraulic system).

7. Remove the transaxle assembly after removing each bolt attached to the engine assembly.

8. Remove the clutch cover assembly. The release bearing is still attached.

9. To separate the release bearing from the clutch cover, rotate the release bearing to gain access to the bearing snap ring.





10. Insert the snap ring pliers under the wave washer to release the bearing.

11. Replace the clutch components as necessary by following the steps in the appropriate Shop Manuals.

NOTE
Do not attach the new release bearing to the clutch cover.





12. Install the release bearing on the fork as shown.

13. Attach the clutch cover without the release bearing to the flywheel while the clutch disc is aligned using the clutch disc guide tool (refer to the appropriate Shop Manuals for the clutch disc guide tool part number).

14. Attach the transaxle assembly to the engine assembly.

NOTE
Make sure not to apply any side loads to the clutch components.

15. Install the release lever on the release fork shaft by aligning notches (release lever attaches only one way on the shaft).

16. After completing step 15, pull the release lever to engage the release bearing into the clutch cover fingers. If there is a click sound, the release bearing and the clutch cover are aligned correctly. If the assembly does not click and snap into place, the release bearing and the clutch cover are not aligned correctly. Repeat steps 13, 14 and 15.

NOTE
Do not apply excessive force on the release lever to engage the release bearing.

17. Reconnect all removed components in the reverse order of removal.

18. Add the specified amount and type of oil into the filler hole (refer to the applicable Shop Manuals for this information).