SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2000
GROUP
Transaxle/Transmission Manual Transaxle System
Return to Main Menu(s):      Mechanical Manual      Electrical Manual

COMPONENTS 
Return to Main Menu(s):      Mechanical Manual      Electrical Manual

DISASSEMBLY 
  1. Remove the front bearing using the special tool (09432-21300).

  1. Remove the inner ring, spacer, 4th gear, needle roller bearing, bearing sleeve, synchronizer rings, 3rd and 4th gear synchronizer hub and sleeve and 3rd gear all together using the special tool (09432-33200).

Return to Main Menu(s):      Mechanical Manual      Electrical Manual

INSPECTION 
INPUT SHAFT
  1. Check the outer surface of the input shaft where the needle roller bearing is mounted for damage or abnormal wear [portion (A)].

  1. Check the splines for damage or wear.

NEEDLE ROLLER BEARING
  1. Install the needle roller bearing on the shaft with the bearing sleeve and gear. Check that it rotates smoothly without abnormal noise or play.

  1. Check the needle roller bearing cage for distortion,

SYNCHRONIZER RING
  1. Check the clutch gear teeth for damage.

  1. Check the internal surface for damage, wear or broken grooves.

  1. Push the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is not within specifications.

    MEASUREMENT SPECIFICATION
    Synchronizer ring 0.5 mm ( 0.02 in )
SYNCHRONIZER SLEEVE AND HUB
  1. Install the synchronizer sleeve on the hub and check that it slides smoothly.

  1. Check that the sleeve is free from damage.

  1. Check for wear of the hub end surfaces (in contact with each gear).

    CAUTION
    Replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
  1. Check for wear of the synchronizer key center protrusion.

  1. Check the spring for weakness, distortion or damage.

GEARS
  1. Check the helical gear and clutch gear teeth for damage or wear.

  1. Check the gear cone for rough surfaces, damage or wear.

  1. Check the gear bore for damage or wear.

Return to Main Menu(s):      Mechanical Manual      Electrical Manual

ASSEMBLY 
  1. Install the synchronizer hub and sleeve so that they are positioned as shown in the figure.

  1. The synchronizer sleeve has teeth missing at six places. Assemble the hub to the sleeve so that the center tooth between the two missing teeth will touch synchronizer key.

  1. Install the synchronizer spring so that the stepped portions will rest on the synchronizer keys.

    CAUTION
    When installing the synchronizer springs, make sure they are not facing the same direction.
  1. Install the 3rd-4th gear synchronizer assembly on the input shaft using the special tool (09432-33300).

    CAUTION
    1. When installing the synchronizer assembly, make sure that the three synchronizer keys are seated correctly in their respective grooves of the synchronizer ring.
    2. After installing the synchronizer assembly, check that 3rd gear rotates smoothly.
  1. Install the bearing sleeve using the special tool (09432-33300).

  1. Install the needle bearing and 4th gear on the input shaft.

  1. Install the spacer and sleeve on the input shaft.

  1. Install the taper roller bearing on the input shaft using the special tool (09432-33300).