HYUNDAI AERO TOWN D6DA 2010 hộp số sàn GEAR SHIFT UPPER DISASSEMBLY

2.Remove power shift assemblyB from control coverA.. Remove control coverA from gear shift housing.. 4.After removing spring pin fixed to shift lever, remove shift lever shaft from the c

• Move each shift fork to see if any part is worn or abnormally operating Replace faulty part if any

• Make sure that no pin and spring is left inside the gear shift housing

1

Remove air hose connected to power shift assembly

2.Remove power shift assembly(B) from control cover(A)

3

Remove control cover(A) from gear shift housing.

4.After removing spring pin fixed to shift lever, remove shift lever shaft from the control cover

• Take care so that the oil seal is not damaged by shift lever shaft key

5.Install the spacer and compression spring by using the special tool

6

Remove selector lever and selection assembly after removing the spring pin fixed to selector lever assembly

7.Remove compression spring, play washer, O-ring and spacer

8.Remove gearshift housing fixing bolts(A)

9.Remove the gearshift housing(B).

10

Remove the back-up lamp switch(A).

11

Remove the split pin(A) and nut of guide bolt

12.Remove the gear shift shaft cap

Remove the shift fork fixing pin and shift head by using tapping rod of diameter 5 mm

14

Set the shift shaft into the neutral position

15.Hold a copper rod against the end of the shift shaft and tap the rod lightly to remove the shaft and its expansion plug When removing the shift shaft, remove the shift head and shift fork

• Take care not to damage the sliding surface of the inside gear shift housing

16 Remove the lock ball(A) from the gear shift housing

• Steel ball may pop up from the hole in removal of the shift shaft Install the safety glass and take care not to lose lock ball and compression spring

17

Remove the inter-lock pin(A)

18

Remove the compression spring(A) from the gear shift housing

19

Remove the guide bolt assembly

1

Check the shift lever shaft and inner shift lever for any damage or worn-out Replace them if any damage or worn-out

2.Check any damage or worn-out for the following parts and replace them if any damage

is detected

Inter-lock pin, inter-lock plunger, compression spring, ball

3

Check the clearance between the shift fork and shift sleeve

4.If the clearance is bigger than the service limit, replace the shift fork or shift sleeve with the new one

Standard : 0.082 ~ 0.137 mm

Service limit : 1.0 mm

5.Check the shift head, shift fork and shift shaft for the damage and worn-out Replace the part if any damage or worn-out is detected

Reassembly

1

Install the guide bolt assembly

2.Install the compression spring(A) to the gear shift housing

Install the inter lock pin to the gear shift housing

4.Install the lock ball(A) to the gear shift housing

5.Install the shift fork and shaft

Apply grease to the shift when installing the shift shaft

6

Install the shift fork double spring locking pin by using tapping rod of diameter 5mm.

7.Install the gear shift shaft cap.

8.Install the guide bolt assembly

9.Install the nut to the guide bolt and fix it by split pin(A)

Install the back up lamp switch(A)

11

Using an ohmmeter, check the continuity between the terminals with in the neutral position (infinity) and with the gear shift shaft in the reverse position (0 ohm)

If faulty, replace the switch

12.Check the relative position and direction of each shift fork and shift head and check the interlock operations

A : 114.9 ± 0.5 mm

B : 113.65~114.65 mm

Measure the shift stroke

Shift stroke

(4th-5th) A : 12.5 mm

(2nd-3rd, reverse-1st) B : 12.0 mm

14

Apply the sealant to the gear shift housing

15.Install the gear shift housing(B) to the transmission case(A) Tightening torque : 44.1~49Nm(4.5~5kgf.m, 32.72~36.35lb-ft)

Install the compression spring, washer, O-ring and spacer

17

Apply the gear oil to the gear shift lever shaft, install the shaft to the control cover

18

Install the control cover(A) to the gear shift housing.

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

19

Install the power shift assembly(B) to the control cover(A)