Hyundai Tucson: Manual Transaxle System / Manual Transaxle Repair procedures

Removal
1.
Remove the following items;
A.
Engine cover.
B.
Air cleaner assembly and air duct.
(Refer to "Intake and Exhaust system" in EM group)
C.
Battery and battery tray.
(Refer to "Charging system" in EE group)
2.
Disconnect the back up lamp switch connector (A).

3.
Remove the control cable assembly (A).
(1)
Remove the snap pin (B) and washer (C).
(2)
Remove the cable bracket mounting bolt (D).

4.
Remove the ground cable (A) from transaxle.

5.
Remove the clutch tube bracket bolt (A).

6.
Remove the transaxle upper mounting bolts (B-2ea) and the start motor mounting bolts (A-2ea).

Tightening torque:
(A) 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
(B) 42.2 ~ 54.0 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

7.
Remove the cowl top cover or wiper motor.
(Refer to "Windshield Wiper/Washer" in BE group.)
8.
Remove the cowl complete assembly panel (A).

9.
Using the engine support fixture (Support SST No.: 09200-2S000, Beam SST No.: 09200-38001), hold the engine and transaxle assembly safely.

10.
Remove the cover (A).

11.
Remove the transaxle mounting support bracket bolt (A).

Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

12.
Remove the transaxle mounting support bracket bolt (A-4ea).

Tightening torque:
58.9 ~ 78.5 N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.8 lb-ft)

13.
Remove the under cover (A).

14.
Remove the side cover (A).

15.
Remove the cover (A).

16.
Remove the following items;
A.
Drive shaft assembly.
(Refer to Driveshaft and axle - "Drive shaft assembly")
B.
Remove the roll rod support bracket (C) after removing bolt (A,B).

Tightening torque :
(A) 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
(B) 107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.1 lb-ft)

17.
Remove the clutch release cylinder assembly (B) after removing the bolts (A-2ea).

Tightening torque:
14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.8 ~ 15.9 lb-ft)

18.
Remove the lower mounting bolts (A-1ea, B-4ea) of lower part of the transaxle, and remove the transaxle assembly by supporting it with a jack.

Tightening torque:
(A) 42.2 ~ 54.0 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
(B) 42.2 ~ 48.1 N.m (4.5 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)

Installation
1.
Installation is the reverse of removal.
   
If the oil seal on the transaxle case side is damaged and fluid is leaking, replace the oil seal with a new unit.
When installing the new oil seal, use the specialized tool (oil seal installer, 09431-26100).
Adding Manual transaxle fluid.
(Refer to "Manual transaxle system" in this group.)
Manual Transaxle Components and Components Location
Components 1. Clutch housing2. Back-up lamp switch3. Control shaft complete 4. Manual transaxle case ...

Back-up Lamp Switch Description and Operation
Description Back up lamp switch is pushed by the reverse lug sliding when select arm, and switches the back up lamp. ...

Other information:

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