HYUNDAI AERO TOWN D6DA 2010 hộp số sàn INPUT SHART REMOVAL

Remove the retainer ring from he output shaft rear bearing.• Be careful with the retainer ring that may pop up while removal.. • If the output shaft assembly is removed from the transmis

Remove the oil seal.

4.Remove the speedometer sensor tone wheel.5.Remove the front bearing mounting bolt.6

Remove the front bearing retainer

• Oil seal is attached inside the front bearing retainer.

• Cover(e.g with aluminum foil)the spline of the input shaft so as not to damage the lop of the oil seal when removing retainer

7.Remove the bearing and input shaft

8.Using a retainer ring plier, remove the retainer ring from the input shaft

• Be careful with the retainer ring that may pop up while removal

9.Using a press, remove the cylindrical bearing

Remove the retainer ring from he output shaft rear bearing.

• Be careful with the retainer ring that may pop up while removal

12.Remove the rear bearing

Attach a jig to the end of the output shaft

• If the output shaft assembly is removed from the transmission without jig, the reverse gear will drop from the shaft and possibly result in personal injury

14

Remove the output shaft assembly from the transmission case

When removing output shaft assembly, remove the synchronizer ring and the cone of the input shaft gear

15.Remove the jig from the end of output shaft

Install the bearing to the output shaft.

4.Apply the gear oil to the outer and inner race

• Be careful not to damage the inner race surface

5.Install the cylindrical bearing by using press.

• Be careful not to damage the inner race surface

6

Install the retainer ring(A)

7.Install the cylindrical bearing

(1)Apply the gear oil to the bearing

(2)Install the spacers at both ends of bearing

• If needed, replace the bearing by units of set.

8.Install the input shaft assembly

9.Install the oil seal

10

Install the front bearing retainer

(1)When installing bearing retainer, align the gasket notch with oil drain hole to assemble the gasket

(2)Apply the grease to the oil seal and input shaft

(3)Apply the sealer to the both ends of gasket

Install the front bearing retainer mounting bolt

Tightening torque : 37.24~49Nm(3.8 ~ 5.0 kgf.m, 27.63~36.35lb-ft)

• Apply sealing tape or sealer to the bolt(A) thread

12.Install the speedometer sensor tone wheel

13

Install the speedometer drive gear

• Be careful not to damage of O-ring and seal lip

Install the oil seal

When installing the oil seal, check right angle alignment and take care not to damage the seal lip Apply grease to the lip

15.Install the rear bearing retainer

Tightening torque : 39.2~49Nm(4~5kgf.m, 29.08~36.35lb-ft)

• Apply liquid sealer or sealing tape to the bolt threads

• Apply liquid sealer to both sides of the gasket

Inspection of the output shaft

(1)Inspect the output shaft backlash

2nd, 3rd, 4th gear 0.1~0.2 mm

(2)Inspect the end play of gears

1

Remove the reverse gear(A)

2.Remove the reverse gear needle roller bearing(A)

3

Remove the retainer ring at the front face of output shaft.

• Be careful with the retainer ring that may pop up while removal

4.Remove the 4th - 5th synchronizer unit(A).

5.Remove the synchronizer cone(A)

6

Remove the needle roller bearing(A).

7.Remove the retainer ring that fixes the 4th gear bushing to the output shaft.

• Be careful with the retainer ring that may pop up while removal

8.Remove the 4th gear housing

9.Remove the 4th gear(A)

Remove the pin.

12.Remove the 3rd - 4th synchronizer unit(A)

Remove the 3rd gear needle roller bearing and spacer.

15.Press the main shaft rear end through the bushing and gears by supporting the assembly on front face of the 2nd gear

• Stay away from the shaft The shaft may drop suddenly resulting in personal injury

Remove the 1st needle roller bearing(A)

20.Remove the 1st gear bushing(A)

21.Remove the constant hub(A)

22.Remove the 2nd gear(A).

23.Remove the 2nd gear needle roller bearing and spacer

24.Remove the sleeves

25.Remove the synchronizer key and head.

• Be careful with the spring that may pop up while removal

26.Remove the compression spring

27.Remove the retainer that fixes the synchronizer ring to gear (3rd , 4th gear)

• Be careful with retainer ring that may pop up in removal

28.Remove the synchronizer cone from the gear.

INSPECTION

INSPECTION OF GEAR AND SHAFT

1

Inspect crack and defect of every gear, and replace it if any defect is found

2.Inspect damage and worn-out of input shaft(A) and replace it if and defect is found

Inspect damage and worn-out of output shaft(A) and replace it if ant defect is found.

Synchronizer unit inspection

Measure the clearance between synchronizer ring and the slanted part of synchronizer cone If the measured clearance lies within the service limit, replace the synchronizer ring and cone.Assembly standard : 1.2 ~ 1.8 mm

Inspect any damage or worn-out of cylindrical bearing, and replace if any defect is found

2.Check the needle bearing for any damage or worn-out If any defect is found, replace the bearing

Oil seal inspection

Check the oil seal for any damage or worn-out If any defect is found, replace the oil seal.Speedometer gear inspection

Check speedometer drive gear and driven gear If any damage or worn-out is found, replace it

REASSEMBLY

1

Install compression spring

• Assemble the synchronizer unit

2.Install synchronizer key and head.

• Be careful with compression spring that may pop up during the assembly

3

Assemble the synchronizer sleeve

4.Install synchronizer cone on the 3rd and 4th gear

5.Fix the gear and synchronizer with the retainer ring.

• Make sure to align the retainer ring to the groove of gear

• Be careful with the retainer ring that may pop out during installation

6

Install spacer and 2nd gear needle roller bearing(A) on output shaft

• Insert the spacer to each bearing

• Apply the gear oil to each needle roller bearing and gear

7.Install the 2nd gear(A)

8.Assemble the 1st, 2nd synchronizer hub(A).

• When assembling hub, place the side with the larger chamfering close to the gear spline face of 1st gear (Chamfering : 1.5 mm) Besides, numbers are marked at the hub side to prevent the mistake in assembly

9.Install the 1st gear bushing Heat the bushing around 85°C with heater and assemble it

to the shaft end

• Do not touch the heated bushing with hands

Install the needle roller bearing(A) for 1st gear.

11

Install the 1st gear(A)

12.Install the constant hub

Install the needle roller bearing(A) for reverse gear

15.Install the reverse gear(A)

16

Hold the thrust washer with the jig

• If output assembly is assembled to transmission without using the jig, reverse gear may drop

Install the needle roller bearing and spacer for 3rd gear

• Place the spacer between 2 bearings

20.Install the pin(A).

21.Install the 4th gear(A)

22.Install the needle roller bearing(A) for 4th gear

23.Install the bushing for the 4th gear.

• Align the bushing grooves with pin

24.Install the retainer ring(A)

(1)Select the retainer ring

(2)Install the retainer ring and make sure to be correctly positioned

• Be careful with the retainer ring that may pop out during installation

(3)Check the clearance.

• Use only the new retainer rings

25.Install the gear needle roller bearing(A)

26.Install the synchronizer cone(A)

27.Assemble synchronizer unit(A) for 4th - 5th gear.

28.Install the retainer ring(A)

(1)Select the retainer ring

(2)Install the retainer ring and make sure to be correctly positioned

• Be careful with the retainer ring that may pop out during installation