Hyundai Elantra HD: Manual Transaxle. Repair procedures (M5CF2) - Manual Transaxle System - Manual Transaxle System - Hyundai Elantra HD 2006–2010 Service ManualHyundai Elantra HD: Manual Transaxle. Repair procedures (M5CF2)

Removal

•
Use fender covers to avoid damaging painted surfaces.
•
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
•
Mark all wiring and hoses to avoid misconnection.
1.
Remove the engine cover (A).
2.
Remove the battery (A) after removing the battery terminal.
3.
Remove the air duct assembly(A).
4.
Remove the air cleaner assembly (C) by disconnecting the clamp (A) and the ECM connector (B).
5.
Remove the ground cable from transaxle (A).
6.
Disconnect the vehicle speed sensor and the back lamp switch integrated connector (A).
7.
Remove the control cable assembly (C) by removing the snap pins (A) and clips (B).
8.
Remove the control cable bracket (A).
9.
Using the special tool (09200-38001), support the engine assembly safely.
10.
Remove the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolts (B-2ea).
11.
After removing the four bolts, take the transaxle insulator mounting bracket (A) off.
12.
Remove the steering joint assembly bolt. (refer to Steering column/shaft in ST group)
13.
Lifting up the vehicle.
14.
Remove the front wheels and tires.
15.
Remove the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut from the front knuckles. (refer to Front suspension system in SS group)
16.
Remove the under shield cover(A,B).
17.
Remove the roll stopper mounting bolts (A,B).
18.
Disconnect the muffler hanger rubber (A).
19.
Supporting the sub frame (A) with a jack and the Special tool (09624-38000), remove the mounting bolts.(refer to Stabilizer removal in SS group)
20.
Disconnect the drive shafts (A,B) from the transaxle.
21.
Remove the clutch release cylinder assembly (A).
22.
Supporting the transaxle with a jack, remove the transaxle lower mounting bolts(A-3ea, B-2ea).
23.
Lowering the jack slowly, remove the transaxle.

Installation

1.
Install the transaxle lower mounting bolts (A-3ea,B-2ea) after fitting the transaxle assembly into the engine assembly.
Tightening torque :
[A] 30-42Nm (3.0-4.2kgf.m, 21.7-30.4lb-ft)
[B] 43-55Nm (4.3-5.5kgf.m, 31.1-39.8lb-ft)

2.
Install the clutch release cylinder assembly (A).
3.
Connect the drive shafts (A,B) to the transaxle.
4.
Supporting the sub frame (A) with a jack and the Special tool(09624-38000), install the mounting bolts. (refer to Stabilizer installation in SS group)
Tightening torque :
140-160Nm (14-16kgf.m, 101-118lb-ft)

5.
Install the muffler hanger rubber (A).
6.
Install the roll stopper bracket bolts. (A,B)
Tightening torque :
50-65Nm (5-6.5kgf.m, 36.2-47.0lb-ft)

7.
Install the under shield cover(A,B).
8.
Install the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut to the front knuckles. (refer to Front suspension system in SS group)
9.
Install the front wheels and tires. (refer to installation in SS group)
10.
Install the steering joint assembly bolt (A). (refer to Steering column/shaft in ST group)
Tightening torque :
18-25Nm (1.8-2.5kgf.m, 13.0-18.1lb-ft)

11.
Install the transaxle insulator mounting bracket bolts (A).
Tightening torque :
60-80Nm (6.0-8.0kgf.m, 43.4-57.9lb-ft)

12.
Remove the special tool (09200-38001).
13.
Install the transaxle upper mounting bolts (A-2ea) the starter motor mounting bolts. (B-2ea).
Tightening torque :
[A] 60-80Nm (6.0-8.0kgf.m,43.4-57.9lb-ft)
[B] 39-60Nm (3.9-6.0kgf.m, 28.2-43.4lb-ft)

14.
Install the control cable bracket (A).
Tightening torque :
15-22Nm (1.5-2.2 kgf.m, 10.8-15.9lb-ft)

15.
Connect the vehicle speed sensor and the back lamp switch integrated connector (A).
16.
Install the control cable assembly (A) by installing the clips (B) and pins (C).
17.
Install the ground cable (A) to transaxle.
18.
Install the air cleaner assembly (C) by connecting the clamp (A) and the ECM connector (B).
19.
Install the air duct assembly (A).
20.
Install the battery (A) and the battery terminal.
21.
Install the engine cover (A).

Manual Transaxle. Components and Components Location (M5CF2)
Components (1) 1. 5th synchronizer key assembly 2. 5th synchronizer hub 3. 5th synchronizer sleeve 4. 5th double cone assembly 5. Needle roller bearing 6. 5th speed ...