Xe ô tô hyundai excel toàn tập hyundai excel - P18

MANUAL
TRANSMISSION
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GENERAL
.........................................
2
MANUAL TRANSMISSION CONTROL
.....................
9
MANUAL TRANSMISSION
........................... 13
MANUAL TRANSMISSION ASSEMBLY
....................
15
INPUT SHAFT
................................. 30
INTERMEDIATE SHAFT
............................
34
OUTPUT SHAFT
.................................... 35
DIFFERENTIAL
..................................... 38
CLUTCH HOUSING
.................................
41
SPEEDOMETER SLEEVE ASSEMBLY
.................
45
GENERAL
GENERAL

SPECIFICATIONS
Manual transmission
Type
Gear ratio 1st
2nd
3rd
4th
Reverse
Final reduction ratio
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
Output shaft pre-load
0.15-0.20 mm (0.006-0.0078 in.) ....
Adjust with spacer
Clearance between 5th shift lug and 3-4
0-0.4 mm
speed shift lug (5-speed only)
(0-0.016 in.) ..............
Adjust with selector spacer
SERVICE STANDARD
Manual transmission
Standard value
Free play of range selector lever end
Approx. 5 mm (0.2 in.)
Spacer for differential pinion backlash adjustment
Thickness

0.75-0.82 mm (0.0295-0.0323 in.)
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
Thickness-ldent. mark
1.31 mm (0.0516 in.)-E
1.40 mm (0.0551 in.)-None
1.49 mm (0.0587 in.)-C
43-2
GENERAL
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
GENERAL
TIGHTENING TORQUE
Nm
kg.cm
Ib.ft
Manual transmission
Extension to transmission
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
60-70
610-710
43-51
33
337
24
12-15
120-150
9-11
9-14
90-140
6.5-10
9-14
90-140
6.5-10
9-14
440-560
31-40

43-55
440-560
31-40
22-32
220-330
16-23
15-22
150-220
11-16
10-12
100-120
7-9
Refer to the table of components
15-21
150-210
11-15
43-53
440-540
32-39
30-34
300-350
22-25
10-11
100-110
7-8
30-34
300-350
22-25
30-34
300-350

22-25
30-41
300-420
22-30
15-21
150-210
11-15
89-107
900-1,100
65-79
30-41
300-420
22-30
128-137
1,300-1,400
94-101
3.0-4.5
30-45
2.5-3.5
15-21
150-210
11-15
27-33
270-340
20-24
30
310
22
NOTE
*Bolt O.D. x Length mm

LUBRICANTS
Recommended lubricant Quantity
Manual transmission
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
2.1 (2.2, 1.8)
As required
As required
As required
43-4
GENERAL
SPECIAL TOOLS
43-5
GENERAL
Tool
(Number and name)
Illustration
Use
09432-21300
Removing plate
1) Removal of the input shaft front bearing
2) Removal of the output shaft 2nd, 3rd and
4th gear
09432-21400

Taper bearing puller
1) Removal of the intermediate shaft
taper bearing inner race
2) Removal of the output shaft taper bear-
ing inner race
3) Removal of the transfer shaft taper bear-
ing inner race
09432-21500
Bearing installer
1) Installation of the input shaft front
bearing
2) Installation of the output shaft synch-
ronizer hub and gear sleeve
09432-21600
Bearing installer
1) Installation of the input shaft
rear bearing
2) Installation of the intermediate shaft
front and rear bearing
3) Installation of the output shaft front and
rear bearing
4) Installation of the taper roller bearing
inner race of transfer shaft (use with
09500-21000)
09432-21700
Bearing outer race installer
1) Installation of intermediate shaft bear-
ing outer race (use with 09500-21000)
2) Installation of output shaft bearing outer
race (use with 09500-21000)

09433-21000
Removing plate
3) Installation of transfer shaft front bear-
ing outer race (use with 09500-21000)
1) Removal of differential ball bearing (use
with 09532-11301)
2) Removal of differential bearing
09437-31000
Shift lever remover
Removal and installation of the shift lever
knob
43-6
GENERAL
Tool
(Number and name)
Illustration
Use
09438-21000
Poppet ball guide
Installation of the poppet ball
43-7
GENERAL
TROUBLESHOOTING
Symptom
Transmission vibration
Oil leakage
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
COMPONENTS
From March, 1987
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.
43-10
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
MANUAL TRANSMISSION

MANUAL TRANSMISSION
COMPONENTS
Nm
kg.cm Ib.ft
O.D. x Length mm (in.)
Bolt identification
A 43-55 430-560
31-40
B
43-55 430-560
31-40
C
22-32 220-330
16-23
D
30-34 300-350
22-25
E
10-12
100-120 7-9
F
15-22
150-220 11-16
REMOVAL,
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.
43-14
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 - V1, actuating the manifold negative
pressure on the H chamber of the select actuator.
Meanwhile, the V2 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 actua-
tor, pulling the select rail to the E range and engaging
the input high gear. The 5th speed is obtained in this
way.
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 V1 nipple, causing the negative
pressure to be actuated on L chamber through V2
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 indi-
cate any abnormality as it is produced by electric
control of the shifting mechanism in the tran-
smission.
43-17
MANUAL TRANSMISSION ASSEMBLY
INSTALLATION OF VACUUM HOSE FOR 5-SPEED MANUAL TRANSMISSION
IDENTIFICATION
Nipple
A
B
C
D
E
F
Nipple
Vacuum hose
Remarks
Ident. Mark
Color
Ident. Mark
Color
llll
White
nnnn
White
-
-
nnnnnn
White

ll
White
nn
White
ll
Green
nn
Green
llll
Green
nnnn
Green
ll
Yellow
nn
Yellow
43-18