SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2000
GROUP
Transaxle/Transmission Manual Transaxle System
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REASSEMBLY 

Assembly procedure is the reverse of removal procedure.

  1. Install the drive shaft oil seal using the special tool (09431-21000).

    NOTE
    Insert the oil seal straightly.
  1. Install the input shaft front oil seal using the special tool (09431-21000).

    CAUTION
    Do not reuse the oil seal.
  1. Install the output shaft oil guide in the direction illustrated.

  1. Install the output shaft bearing outer race using the special tools (09532-11500, 09500-11000).

  1. Install the control shaft assembly.

  1. Install the differential gear assembly.

  1. Insert the output shaft, inclining the differential assembly.

    Insert the input shaft, inclining the output shaft.

  1. Install the input shaft bearing retainer.

    CAUTION
    Apply a three BOND 1303 on the hex-bolts.
  1. Reassembly the shift rail assemblies.

    1. place the first and second speed synchronizer sleeve to the second gear position in order to get installing space of 1st 2nd shift rail assembly.
    1. Place the third and fourth speed synchronizer sleeve to neutral position.
    1. Install the shift rail and fork assemblies.
  1. Reassembly of spring pin.

    1. Install the spring pins using the special tool (09414-11100) or pin punch.
      CAUTION
      Do not reuse the spring pin.
    1. When installing, make sure that the slit of the spring pin is aligned with center line of the shift rail.
  1. Install the reverse gear shaft and reverse gear in the direction illustrated.

  1. Install the reverse shift lever.

  1. Install the drive shaft oil seal in the transaxle case using the special tool (09431-21200).

    CAUTION
    Do not reuse the oil seal.
  1. Install the input shaft bearing outer race and spacer using the special tools (09432-33400, 09500-21000).

  1. Install the output shaft bearing outer race and spacer using the special tools (09500-11000, 09532-11500)

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REASSEMBLY (continued) 
  1. Installation of spacer.

    1. Place two pieces of rosin-core solder with 3 mm in diameter on the bearing outer race as illustrated.
    1. Install the transaxle case temporarily and tighten the bolts to the specified torque, then remove the transaxle case.
    1. Detach the crushed solders.
    1. Measure the thickness of the crushed solder. Select and install the proper spacers which complete following specification.
      MEASUREMENT SPECIFICATION
      Input shaft rear bearing end play 0-0.05L mm
      Output shaft rear bearing end play 0.10T-0.15T mm
      Differential shaft rear bearing end play 0.20T-0.25T mm

T: Indicates tightening of - (minus) direction of endplay

L: Indicates loosening of + (plus) direction of endplay

  1. Install the oil guide in the transaxle case.

  1. Apply the specified sealant to the clutch housing side of the transaxle case.

    Specified sealant: MS721-40.

  1. Install the transaxle case onto the clutch housing assembly and tighten the bolts.

    TORQUE SPECIFICATION
    Transaxle case 35-42 Nm ( 350-420Kg kg·cm, 26-31 lb·ft )
  1. Center the reverse idler gear shaft with screw driver.

  1. Tighten the reverse idler gear shaft bolt to the specified torque.

    TORQUE SPECIFICATION
    Reverse gear shaft bolt 43-55 Nm ( 430-550 kg·cm, 32-41 lb·ft )
  1. Install poppet balls, poppet springs, and seal bolts.

  1. Install the output shaft gear using the special tool (09432-33300).

  1. Install the 5th speed gear, needle roller bearing, synchronizer ring and synchronizer hub.

    CAUTION
    Place the oil groove of synchronizer hub toward the fifth speed gear.
  1. Install the fifth speed gear shift fork and the synchronizer sleeve at the same time.

  1. Reassembly of locking nut.

    1. Shift the transaxle into 3rd and 5th gear.
    1. Tighten the lock nut to the specified torque.
      TORQUE SPECIFICATION
      Lock nut 140-160 Nm ( 1400-1600 kg·cm, 102-115 lb·ft )
    1. Stake the lock nut.
  1. Install the spring pin using the special tool (09414-11100) or pin punch.

    CAUTION
    DO not reuse the spring pin.
  1. When installing, make sure that the slit of the spring pin is aligned with the center line of the shift rail.

  1. Apply the specified sealant to the rear cover and install the rear cover.

    Specified sealant: MS 721-40

  1. Install the speedometer driven gear assembly.

    TORQUE SPECIFICATION
    Speedometer driven gear 3-5 Nm ( 30-50 kg·cm, 2.3-3.6 lb·ft )
  1. Install the back up light switch.

    TORQUE SPECIFICATION
    Back up light switch 30-35 Nm ( 300-350 kg·cm, 22-25 lb·ft )
  1. Install the mounting bracket.

    TORQUE SPECIFICATION
    Transaxle mount bracket to transaxle 60-80 Nm ( 600-800 kg·cm, 43-58 lb·ft )
  1. Install the select lever assembly.

    TORQUE SPECIFICATION
    Select lever assembly 15-22 Nm ( 150-220 kg·cm, 11-16 lb·ft )