Xe ô tô hyundai excel toàn tập hyundai excel - P18

Tài liệu xe ô tô hyundai excel toàn tập hyundai excel

TRANSMISSION Return To Main Table of Contents

GENERAL 2

MANUAL TRANSMISSION CONTROL 9

MANUAL TRANSMISSION 13

MANUAL TRANSMISSION ASSEMBLY 15

INPUT SHAFT 3 0 INTERMEDIATE SHAFT 34

OUTPUT SHAFT 35

DIFFERENTIAL 38

CLUTCH HOUSING 4 1 SPEEDOMETER SLEEVE ASSEMBLY 45

4-speed, Floor-shift control 4.266

2.365 1.467 1.105 4.109 3.470 Type

Gear ratio 1st

2nd 3rd 4th 5th Reverse Final gear ratio

5-speed, Floor-shift control 4.266

2.365 1.467 1.105 0.955 4.109 3.470 Speedometer gear ratio

Quantity of oil lit (U.S.qts., Imp.qts.)

Backlash between differential side gear

and pinion

Drive 19/Driven 16 2.1 (2.2, 1.8) 0.025-0.150 mm (0.001-0.006 in.) Adjust with spacer

Differential case end play 0-0.15 mm (0-0.006 in.) Adjust with spacer Intermediate shaft end play 0-0.05 mm (0-0.002 in.) Adjust with spacer

speed shift lug (5-speed only) (0-0.016 in.) Adjust with selector spacer

SERVICE STANDARD

Manual transmission

Standard value

Spacer for differential pinion backlash adjustment

0.83-0.92 mm (0.0327-0.0362 in.) 0.93-1.00 mm (0.0366-0.0394 in.) 1.01-1.08 mm (0.0398-0.0425 in.) 1.09-1.16 mm (0.0429-0.0457 in.) 1.17-1.25 mm (0.0460-0.0492 in.) 1.26-1.34 mm (0.0496-0.0527 in.) Spacer for differential case end play adjustment

1.40 mm (0.0551 in.)-None 1.49 mm (0.0587 in.)-C

43-2

G E N E R A L

Snap ring for input shaft

Thickness-ldent color

1.58 mm (0.0622 in.)-B 1.67 mm (0.0657 in.)-A 1.76 mm (0.0693 in.)-F 1.85 mm (0.0728 in.)-G 1.94 mm (0.0764 in.)-H 2.03 mm (0.0799 in.)-1 2.12 mm (0.0835 in.)-J 2.21 mm (0.0870 in.)-K 2.24 mm (0.0882 in.)-None 2.31 mm (0.0909 in.)-Bule 2.38 mm (0.0937 in.)-Brown Spacer for intermediate and outputshaft end

play or preload adjustment

Thickness

Selector spacer for shift lug clearance (5-speed only)

Thickness-ldent mark

1.84 mm (0.0724 in.) 1.87 mm (0.0736 in.) 1.90 mm (0.0748 in.) 1.93 mm (0.0760 in.) 1.96 mm (0.0772 in.) 1.99 mm (0.0783 in.) 2.02 mm (0.0795 in.) 2.05 mm (0.0807 in.) 2.08 mm (0.0819 in.) 2.11 mm (0.0831 in.) 2.14 mm (0.0843 in.) 2.17 mm (0.0854 in.) 2.20 mm (0.0866 in.) 2.23 mm (0.0878 in.) 2.26 mm (0.0890 in.) 2.29 mm (0.0902 in.) 2.32 mm (0.0913 in.) 2.35 mm (0.0925 in.) 2.38 mm (0.0937 in.) 2.41 mm (0.0949 in.) 2.44 mm (0.0961 in.) 2.47 mm (0.0972 in.) 2.50 mm (0.0984 in.) 2.53 mm (0.0996 in.) 2.56 mm (0.1008 in.) 2.59 mm (0.1020 in.) 2.62 mm (0.1031 in.) 2.65 mm (0.1043 in.) 2.68 mm (0.1055 in.) 0.6 mm (0.024 in.)-G 0.9 mm (0.035 in.)-F 1.2 mm (0.047 in.)-E 1.5 mm (0.059 in.)-D 1.8 mm (0.071 in.)-C 2.1 mm (0.083 in.)-B 2.4 mm (0.094 in.)-A 2.7 mm (0.106 in.)-None

43-3

Shift rod set screw

Insulator to extension rod

Bracket assembly attaching bolt

Control cable attaching bolt

Control cable clamp attaching bolt

Transmission mounting bolt

Starter motor mounting bolt

Bell housing cover to transmission (8 x 20)*

Bell housing cover to transmission (8 x 14)*

Engine transmission

Clutch cover bolt

Transmission mounting bolt (M10-7T)

Transmission mounting bolt (M8-10T)

Front cover bolt

Oil filler plug

Oil drain plug

Housing-to-case tightening bolt

Front retainer bolt

Input shaft locking nut

Transmission mounting bracket bolt

Differential drive gear bolt

Speedometer sleeve plate bolt

Reverse shift lever support bracket bolt

Poppet plug bolt

Backup lamp switch

Manual transmission oil

lit (U.S.qts., Imp.qts.)

Shift lever, bushing contacting surface

Dust cover inside surface

Shift lever sliding portion

API classification GL-4 Wheel bearing grease SAE J310a, NLGI grade #2 EP

SPECIAL TOOLS

43-5

Taper bearing puller

1) Removal of the intermediate shaft taper bearing inner race

2) Removal of the output shaft taper ing inner race

3) Removal of the transfer shaft taper ing inner race

09432-21700

Bearing outer race installer

1) Installation of intermediate shaft ing outer race (use with 09500-21000) 2) Installation of output shaft bearing outer race (use with 09500-21000)

bear-09433-21000

Removing plate

3) Installation of transfer shaft front ing outer race (use with 09500-21000) 1) Removal of differential ball bearing (use with 09532-11301)

bear-2) Removal of differential bearing

09437-31000

Shift lever remover

Removal and installation of the shift lever knob

43-6

Tool

09438-21000

Poppet ball guide

Installation of the poppet ball

4 3 - 7

Loose transmission assembly

Does not shift to 5th (M/T)

Probable cause Broken gear shift control Worn or pitting due to improper tooth Housing misaligned

Worn seals or gaskets Broken transmission mount Mounting bolts loose Malfunctioning actuator Malfunctioning vacuum control Short circuit in vacuum control

Remedy Replace

Replace Realign Replace parts as required Replace

Retighten bolts Repair or replace as required Replace

Replace

43-8

MANUAL TRANSMISSION CONTROL

MANUAL TRANSMISSION CONTROL

GEARSHIFT LEVER

Removal

1 Remove the floor console box.

2 On vehicles with rear heater duct, remove the rear heater duct.

3 Remove the shift lever assembly attaching nuts from the floor.

4 Pull the shift lever assembly downward from the vehicle.

5 Remove the extension rod from the transmission.

MANUAL TRANSMISSION CONTROL

6 After removing the lock wire, remove the shift rod set screw,

and then remove the shift rod from the transmission.

7 Remove the shift rod and extension rod as an assembly.

8 Remove the dust cover at the end of the shift lever.

9 After the split pin has been removed, remove the shift rod.

10 Remove the extension rod to insulator attaching bolt and

remove the extension rod.

11 Remove the dust cover and remove the bushing.

Inspection

1 Check the shift rod joint for wear, sticking or rough movement.

2 Check the rubber parts for damage or deterioration.

3 Check all bushings for wear and damage.

4 Check the return spring for deterioration.

4 3 - 1 0

MANUAL TRANSMISSION CONTROL

Installation

1 Apply the specified wheel bearing grease to the following areas:

(a) Dust cover inside surface

(b) Shift lever and bushing contacting surface

(c) Shift lever sliding portion

Recommended wheel bearing grease

Wheel bearing grease SAE J310a,

NLGI grade #2 EP.

2 Install a new lock wire to the set screw of the shift rod to prevent

looseness.

43-11

1 Remove the battery.

2 On vehicles with a 5-speed transmission, disconnect the

con-nector of the select control valve.

NOTE:

Do not reuse the collar removed when the pin for coupling

the actuator to the shaft is removed, but use a new part.

3 Remove the speedometer cable.

4 Remove the clutch control cable.

5 Disconnect the connector of the backup lamp.

43-12

MANUAL TRANSMISSION

6 Remove the harness from the starter motor.

7 Remove the transmission to engine coupling bolts from the top

side of the transmission.

8 Remove the starter motor.

9 Lift up the vehicle and remove the under cover.

10 Drain the transmission oil.

11 Remove the extension rod and shift rod from under the engine

compartment.

12 After the stabilizer bar has been removed from the lower arm,

remove the lower arm at the body side, remove the right and

left drive shafts, and hold them in appropriate positions (Refer

FRONT SUSPENSION).

MANUAL TRANSMISSION

13 Support the lower part of the transmission by using a

trans-mission jack.

CAUTION

Support a wide area of the transmission so that the oil pan is

not partially pressed when supported.

14 Remove the bell housing cover.

15 Remove the bolts connecting the transmission with the engine

from under the engine compartment.

16 Remove the transmission mount insulator bolt.

17 Remove the blind cover from inside the right fender shield and

remove the transmission bracket assembly.

18 Remove the transmission mount bracket.

19 Slide the transmission assembly rightward from the vehicle

and then take it out downward.

INSTALLATION

1 Install the transmission by reversing the procedures, and

torque all part to specifications during installation.

2 Refill with transmission oil to the specified level.

Recommended oil API classification GL-4

Quantity 2.1 lit (2.2 U.S.qts., 1.8 Imp.qts.)

3 Adjust the play of the clutch control cable.

4 Operate the shift lever to confirm that the gears of the

trans-mission are positively changed over.

4 3 - 1 4

MANUAL TRANSMISSION ASSEMBLY

MANUAL TRANSMISSION ASSEMBLY

SECTIONAL VIEW

4-speed Manual Transmission

43-15

MANUAL TRANSMISSION ASSEMBLY

5-speed Manual Transmission

43-16

MANUAL TRANSMISSION ASSEMBLY

OPERATION OF 5-SPEED TRANSMISSION

1 When the control lever is shifted to the 5th position,

the control finger engages with the 5th speed shift

lug, shifting the 3-4th speed shift rail to the 4th

speed side with the 5th shift lug, and the 4th speed

gear is engaged.

2 When the select lever moves to the 5th speed position,

the select switch is turned ON simultaneously.

3 When signals from the select switch enter the

con-trol relay, the relay excites the solenoid of the select

control valve and turns it ON.

4 When the select control valve is ON, the valve closes

the atmosphere side of V 1 nipple and opens the

pas-sage of M - V 1 , actuating the manifold negative

pressure on the H chamber of the select actuator.

Meanwhile, the V 2 nipple side is opened to the

atmosphere, allowing the atmospheric pressure to

enter the L chamber.

5 The pressure difference between H chamber and L

chamber actuates the diaphragm of the select tor, pulling the select rail to the E range and engaging the input high gear The 5th speed is obtained in this way.

actua-6 When the control lever is returned from 5th speed, the select switch is turned OFF, and the solenoid of the select control valve is also turned OFF by a relay Then, the atmospheric pressure is introduced to H chamber through V 1 nipple, causing the negative pressure to be actuated on L chamber through V 2

nipple As a result, the select rail is pulled to the P range and the input low gear is engaged.

NOTE:

A slight clicking sound may be heard when shifting

to 5th or reverse gears This sound does not cate any abnormality as it is produced by electric control of the shifting mechanism in the tran- smission.

indi-4 3 - 1 7

MANUAL TRANSMISSION ASSEMBLY

INSTALLATION OF VACUUM HOSE FOR 5-SPEED MANUAL TRANSMISSION

MANUAL TRANSMISSION ASSEMBLY

COMPONENTS

4-speed Manual Transmission

1 Backup light switch

17 Reverse idler gear shaft

18 Reverse idler gear

20 Reverse shift lever assembly

31 Intermediate gear assembly MOTE

33 Bearing retainer For reassembly, reverse order of disassembly.

34 Input shaft assembly

35 Bearing outer race

36 Clutch housing

43-19

MANUAL TRANSMISSION ASSEMBLY

11 Bearing outer race

12 Intermediate gear assembly

13 Speedometer driven gear assembly

14 Reverse idler gear shaft

15 Reverse idler gear

16 Reverse shift gear

17 Output shaft assembly

18 Bearing outer race

35 Clutch cable bracket

36 Backup light switch

For reassembly reverse order of disassembly.

4 3 - 2 0

MANUAL TRANSMISSION ASSEMBLY

DISASSEMBLY

1 Remove the transmission mounting bracket.

2 Remove the two select actuator mounting bolts (for 5-speed

only).

3 Remove the clamp for harness of select switch (for 5-speed

only) and backup light switch.

4 Remove the backup light switch and the steel ball.

5 Remove the select switch (for 5-speed only).

6 Pull the select actuator to remove its rod and shift rail

connec-tion from transmission (for 5-speed only).

7 Remove the collar and pin, and then remove the select actuator

(for 5-speed only).

NOTE:

Do not reuse the collar when reassembly Use a new part.

8 Remove the speedometer gear assembly locking bolt.

9 Pull the speedometer gear assembly from the clutch housing.

10 Remove the transmission to clutch housing tightening bolt.

11 Remove the transmission case.

12 Remove the gasket.

13 Remove the spacer for differential end play adjustment.

43-21

MANUAL TRANSMISSION ASSEMBLY

14 Remove the three poppet plugs and gasket, and then three

poppet springs and steel balls.

15 Pull the reverse idler gear shaft and remove reverse idler gear.

16 Remove the reverse shift lever from clutch housing.

17 Remove reverse shift rail.

18 Use a pin punch to drive the spring pins from the shift forks and

shift rails.

19 Remove the selector spacer (for 5-speed only).

43-22

MANUAL TRANSMISSION ASSEMBLY

20 Pull the 1-2 shift rail from clutch housing then remove the 3-4

shift rail Next, remove 1-2 shift rail and fork assembly,

together with 3-4 shift rail and fork assembly.

21 Remove the two interlock plungers from the clutch housing.

22 Remove the 5th speed shift lug (for 5-speed only).

23 Remove the output shaft assembly.

24 Remove the differential assembly from clutch housing.

25 Remove the poppet plug, the poppet spring and the steel ball

for select shift rail.

26 Remove the input shaft bearing retainer.

27 Remove the input shaft assembly together with the select shift

fork, rail and intermediate shaft.

4 3 - 2 3

MANUAL TRANSMISSION ASSEMBLY

REASSEMBLY

1 Turn the sub gear in direction of arrow to align 8 mm (0.31 in.)

hole in the intermediate gear with that the sub gear, and then

insert 8 mm (0.31 in.)-diameter, 35 mm (1.38 in.)-long dummy

pin through the intermediate gear into sub gear hole.

2 Assemble the select shift fork and rail assembly to the

synchron-izer sleeve of input shaft, and then install these components and

intermediate shaft as a unit.

3 Install the front bearing retainer and tighten the three bolts to

15 to 21.5 Nm (150 to 220 kg.cm, 11 to 15.5 Ib.ft).

4 Install the differential assembly to the clutch housing.

5 Install the output shaft assembly.

6 Make sure that the gears are meshed properly, and then remove

dummy pin from the sub gear and intermediate gear.

43-24

MANUAL TRANSMISSION ASSEMBLY

7 Install 5th speed shift fug to pin on the clutch housing.

CAUTION

Pay attention to the direction of installation.

If the shift lug is installed the wrong way, hard shifting may

result.

8 Insert the two interlock plungers into the holes in the clutch

housing.

9 Install 1-2 shift rail assembly together with 3-4 shift rail

assembly or 3-4-5 shift rail assembly Install one shift rail into

its clutch housing hole, and then install the other It is

impossi-ble to install both shift rails at the same time because of

interference of interlock plunger.

10 Using Special Tool 09414-11100 or blunt punch, drive in

spring pins.

This spring pin must be driven in with its slit on shift rail center

line Make sure both ends of spring pin protrude same

distance.

11 Select the spacer to make the adjustment to the specified

clearance between the 3-4 shift lug and 5th shift lug Then

install the select spacer.

Clearance between 3-4 shift lug and 5th shift lug

0.1-0.5 mm (0.004-0.020 in.)

MANUAL TRANSMISSION ASSEMBLY

Kind of Select Spacers

12 Install the reverse shift rail into the clutch housing.

13 Install the reverse shift lever, and tighten the two bolts to 17

Nm (173 kg.cm, 13 Ib.ft).

14 Install reverse idler gear with chamfered side upward, and

then insert idler gear shaft through the gear into housing.

15 Place the reverse shaft rail in neutral position, and then

mea-sure dimension “A” in the illustration If dimension “A” is less

than standard value, replace reverse shift lever assembly.

Dimension A

37.05-38.65 mm (1.458-1.521 in.)

16 Clean gasket surfaces of clutch housing and transmission

case.

17 Adjust the output shaft, intermediate shaft and differential

case end play or preload as follows:

(a) Remove the outer races of output shaft and intermediate

shaft bearings from transmission case.

43-26