 printable version
Transmission
Manual Transmission
| Fig. 3.22. Manual Transmission
|
| Fig. 3.23. Transmission (information for installation)
|
A mechanical five-speed transmission M5AF3 shown in Fig. 3.22 and 3.23. Transmission ratio, aggregated from different engines are shown in Table. 3.1.
Table 3.1 Ratios manual gearbox Transfer gearbox | Engine capacity, l | eleven | 13 | 15 | 16 | I | 3,615 | 3,615 | 3,615 | 3,615 | II | 1,950 | 1,950 | 1,950 | 1,950 | III | 1,286 | 1,286 | 1,286 | 1,286 | IV | 0.971 | 1,030 | 0 971 | 1,031 | V | 0.780 | 0.825 | 0.825 | 0.825 | Reverse | 3,250 | 3,250 | 3,250 | 3,250 | The main transfer | 4,294 | 3,842 | 3,650 | 3,650 |
For the repair and maintenance of transmission, the following special tools and accessories: - Yoke for hanging the engine when removing and installing transmission (catalog number spare parts and accessories 09200-38001); - A set of supports beams for hanging the engine when removing and installing transmission (catalog number spare parts and accessories 09200-1S000).
Data for inspection and adjustment, mm Axial backlash rear bearing a primary shaft | 0,01-0,09 | Axial internal clearance secondary shaft | 0.05-0.10 | Bearing preload Differential | 0.15-0.20 | Axial clearance pinion main transmission | 0,025-0,15 | The axial clearance of the front bearing a primary shaft | 0.01-0.12 |
Checking and replacing the oil in a mechanical transmission Checking the oil level Make sure that no leakage of oil from the gearbox. Remove the oil filler plug and check oil level. If contaminated oil refill with clean oil.
NOTE The oil level should be at the lower edge of the hole. By reducing the level, add oil until it begins to flow, and tighten the plug. |
Remove the oil filler plug and a finger check the oil level. Change the oil in the gearbox, if it is noticeably contaminated or that viscosity. Change of oil Place the vehicle on level ground, remove the oil drain plug and drain the oil. Screw the oil drain plug with a new seal torque 30-35 Nm.
| Fig. 3.24. Oil filler plug gearbox
|
Fill with fresh oil through the filler hole (Fig. 3.24) to the level of its lower edge.
NOTE Capacity of the gearbox - 2.15 liters. |
Recommended Oil - SAE 75W-90 (API-GL-4).
Removal and installation of a mechanical transmission Disconnect the battery and remove the battery. Remove the battery tray by unscrewing the five bolts of its fastening.
| Fig. 3.25. Bolts of bracket battery tray
|
| Fig. 3.26. Bolt the bottom of the air filter housing
|
Remove the air filter. First, remove the top of the filter, and then the lower part (Fig. 3.26). One of the three bolts located at the bottom of the upper cover of the casing.
| Fig. 3.27. Bracket bolts of the air filter
|
Remove the reverse gear switch. Unscrew the clutch slave cylinder.
| Fig. 3.28. The locking pin tip of a cable shift
|
Remove the locking pin tip of a cable of a gear change (Fig. 3.28).
| Fig. 3.29. The locking pin tip gear selection cable
|
Remove the locking pin tip gear selection cable (Fig. 3.29).
| Fig. 3.31. Mounting Screw starter
|
| Fig. 3.30. Tab washers shells rope gear and gear selection
|
Remove the lock washer cable sleeve gear and gear selection (Fig. 3.31). Disconnect the flexible shaft drive speedometer. Remove the front wheel.
| Fig. 3.32. Bolt gearbox to engine
|
Remove the upper bolt transmission to the engine (Fig. 3.32). Lift the car and remove the brake caliper. Disconnect the tie rod of the strut. Drain the oil from the gearbox by removing the drain plug. Remove the wheel speed sensor and unscrew the bolt knuckle.
A WARNING When installing the device, take care not to damage the hook of the top cover of the housing. |
| Fig. 3.33. Branch of the drive shaft on the gearbox
|
Remove the drive shaft (Fig. 3.33) and remove the wheel hub nut. Install yoke (catalog number spare parts and accessories 09200-38001) for hanging the engine when removing and installing the gearbox bearings. Unscrew Transmission Mount:
| Fig. 3.34. Bolts Transmission Mount to a body
|
| Fig. 3.35. Bolt elastic support transmission
|
| Fig. 3.36. Bolt rear bracket gearbox
|
Remove the rear mounting bracket gearbox lifting the car (Fig. 3.36). Uncover the clutch. Set a rack with gear transmission.
NOTE Avoid unnecessary is extruded gaskets, as this may damage them. |
Remove the lower bolts of a transmission to the engine. Remove the gearbox. Installing gearbox is carried out in reverse order. Make sure that no leakage of oil from the gearbox.
Replacing the oil seal of the differential Disconnect the drive shaft from the transmission as specified in the "front-wheel drive."
| Fig. 3.37. Gland Differential
|
09431-21200 mandrel press in new shaft seal in the gearbox jack. Apply a smooth gear oil seal lip HYUNDAI GENUINE PARTS MTF 75W-90 grade API GL-4.
The drive gear
| Fig. 3.38. Cable drive gear
|
Withdrawal
| Fig. 3.39. The shift lever is removed from the handle
|
| Fig. 3.40. Removing the center console
|
| Fig. 3.41. Bolts switching cables and gear selection to the bottom of the dashboard
|
Unscrew the cables to the bottom of the instrument panel (Fig. 3.41). Remove the locking pin tip of a cable of a gear change (see. Subsection "Removing and installing transmission"). Remove the locking pin tip gear selection cable (see. Subsection "Removing and installing transmission"). Remove the sheath stop switch and gear selection (see. Subsection "Removing and installing transmission"). Remove the shift lever assembly. Technical condition Check the following: - The correct action gear selector cable and the absence of his injuries; - The correct action rope gear and the absence of his injuries; - Protective covers tips of cables for damage; - Sleeve for wear, abrasion, seizure, decreased mobility and other damage; - Springs for loose or damaged. Installation of cables of a drive gear is carried out in reverse order.
The shift lever
| Fig. 3.42. Gear lever: 1 - shift knob; 2 - rod gear lever; 3 - finger; 4 - a cover; 5 - theft; 6 - the case; 7 - a cable of a gear change; 8 - a cable of a choice of transfers; 9 - select lever
|
Automatic transmission Technical specifications Model ..... A4AF3 ..... Four-Type, with one reverse gear Type torque converter ..... tricycle with guide vanes, single-stage rocket with two wheels Ratios gearbox, aggregated with different engines, are shown in Table. 3.2.
Table 3.2 Transmission ratio Transfer gearbox | Engine capacity, l | 13 | 15 | 16 | I | 2,846 | 2,846 | 2,846 | II | 1,581 | 1,581 | 1,581 | III | 1,000 | 1,000 | 1,000 | IV | 0.685 | 0.685 | 0.685 | Reverse | 2,176 | 2,176 | 2,176 | The main transfer | 3,656 | 3,443 | 3,656 |
Applicable special tools and accessories: - Yoke for hanging the engine when removing and installing transmission (catalog number spare parts and accessories 09200-38001); - A set of supports beams for hanging the engine when removing and installing transmission (catalog number spare parts and accessories 09200-1S000);
NOTE The adapter is used in conjunction with devices 09452-21002 and 09452-21500. |
NOTE Check the pressure gauge is used in conjunction with devices 09452-21001 and 09452-21002. |
- Adapter for connection of a test pressure gauge to check the pressure oil (catalog number spare parts and accessories 09200-21002); - Adapter for connection of a test pressure gauge to check the oil pressure (catalog number spare parts and accessories 09452-21002); - Pressure gauge to check the oil pressure (catalog number spare parts and accessories 09452-21500).
Applicable fluids and lubricants Place of application | Name | Volume | Carter automatic transmission | Hydraulic fluid GENUINE HYUNDAI ATF SP-III | 6.7 l | The sealing edge seals differential output shafts | Working fluid | As needed | The surface of the sliding sleeve | Grease for chassis SAE J310, NLGI No. 0 | Also | The friction surface of the selector lever | Multipurpose grease SAE J310, NLGI No.2 | > |
Checking the oil level in an automatic transmission Complete the trip by car to warm the oil of an automatic transmission to normal working temperature (80-90 ?� C). Place the vehicle on level ground. Alternately, set the selector lever to the inclusion of all transfers to fill the torque converter and hydraulic oil, then set the selector lever in position (neutral). Before removing the dipstick, wipe off the dirt around his hole. After that, remove the dipstick and check the oil. Transmission must be repaired if at least one of the following signs of decline in the quality of oil: - The smell of "burning" oil; - A significant darkening of the color of the oil; - The presence of large amounts of a marked metallic particles in the oil.
NOTE Insufficient oil level can cause a variety of disorders of the gearbox, since the pump together with the oil will enter the air. If air enters into the oil, air bubbles are formed. As a result, there are fluctuations in oil pressure that becomes the cause of the delay shift, slip clutches and brakes. |
The oil level should be at the mark "HOT" (hot) probe. By reducing the level of top up to the mark "HOT". Use transmission oil GENUINE DIAMOND ATF SP-III. It is unacceptable excess of the normal level of oil. When filling in the gearbox housing an excessive amount of oil is foamed gears, which leads to malfunction of the same, as when there is insufficient oil level, as well as to the rapid degradation of the oil. In both cases, the formation of air bubbles causes overheating and premature oxidation of the oil, resulting in disturbed normal operation valves, clutches and actuators. In addition, foaming causes the release of oil through the vent gearbox that during the inspection of the box can be perceived as an oil leak.
| Fig. 3.43. Dipstick automatic transmission
|
| Fig. 3.44. The limits of normal levels as measured by oil dipstick
|
A WARNING During this test the front and rear of the vehicle must not be people. |
Check converter lock
NOTE The oil should be warmed up to normal operating temperature (80-90 ?� C). The coolant temperature must also be normal working (about 80-90 ?� C). |
When checking the torque converter lock-determined maximum engine speed at full load and position and selector lever. At the same time check that the freewheel stator torque converter and clutch holding capacity of transmission and brakes and downshift backing.
A WARNING Press the pedal to stop only for such time as is necessary to maximize the tachometer, and in any case does not hold the pedal down more than 5 seconds. If necessary, repeat the test converter lock previously run the engine for 2 min at engine speed of about 1000 min -1; the selector lever must be in neutral to reduce the temperature of the oil. |
Check the oil level in the gearbox. Place a block under the rear wheels. Connect control tachometer. Fully tighten the parking brake lever until it stops and press the brake pedal. Start up the engine. With the gear selector in position to stop, press the accelerator pedal to get the maximum tachometer readings. The engine speed at the time of the torque converter lock - 2200-2800 min -1. Set the selector lever to and recheck torque converter lock as described above. Possible test results. 1. The engine speed when the torque converter is locked above the norm in finding the selector lever in position . If the engine speed at which the torque converter lock, higher than normal, the cause is slipping clutch and rear freewheel gearbox. In this case, check the hydraulic system to determine the cause of slipping. 2. The engine speed when the torque converter is locked above the norm in finding the selector lever in position . If the engine speed at which the torque converter lock, higher than normal, the cause is slipping forward clutch or brake overdrive and reverse transmission. In this case, check the hydraulic system to determine the cause of slipping. 3. The engine speed when the torque converter is locked below the norm in finding the selector lever in position or . If the engine speed at which the torque converter lock, below normal, the reason for this is the lack of power developed by the engine, torque converter or a malfunction. Check the engine for combustion misfires, a violation of the ignition timing is correct gaps in the regulation mechanism of the valve. If the motor is defective, the defective converter.
Check the drive switch Check selector lever action Move the selector lever to all positions, check the smoothness and clarity of its stroke switch. Check the operation of the selector lever position indicator. Make sure that the selector lever is set to all positions. Start up the engine and make sure the vehicle starts to move forward travel when moving the selector lever out of position position and reversing during the installation of the lever to position . In violation of the selector lever to adjust the cable drive control and selector lever sleeve. Check moving parts of the selector lever for wear.
NOTE When adjusting the switch housing Make sure that the housing has not dropped from the O-ring. Tighten the bolt without using excessive force. |
Adjust the selector switch Set the selector lever in position (neutral).
| Fig. 3.45. Selector lever
|
Disconnect the cable from the lever of a drive of an accelerator (Fig. 3.45), loosen the lock nut. Set the selector lever in position (neutral).
| Fig. 3.46. Adjust the selector switch: 1, 3 - selector lever; 2 - selector switch; 4 - bolts selector switch
|
Turn the selector switch housing, align the end of the selector lever 12 mm wide with a portion of the switch body flange width of 12 mm (Fig. 3.46). Tighten the bolts (two bolts) torque 10-12 Nm. Make sure that the selector lever is in position (neutral). Rotate the nut with a fillet, click the slack cable management and ensure smooth movement of the selector lever.
NOTE Before assembling, apply sealant DC780 or the middle part of the same thread of the adjusting screw. |
During the test drive, ensure the correct and precise shifting. Adjust the mode switch Kick-down Carefully remove the dirt around the adjusting screw mode switch Kick-down. Loosen the lock nut of the screw. Double loosen and tighten the adjusting screw to 5 Nm. Tighten adjusting screw to 5 Nm and then unscrew it by about 1/3 turn. Tighten the locknut screw torque 15-22 Nm. Adjust the line pressure
| Fig. 3.47. Oil drain plug gearbox housing
|
Drain the oil from the gearbox. Oil drain plug gearbox housing is shown in Fig. 3.47.
NOTE The change in pressure on one turn of the adjusting screw is 0.39 kgf / cm 2. |
| Fig. 3.48. Bolts transmission oil pan
|
| Fig. 3.49. Oil Filter Transmission
|
| Fig. 3.50. Oil temperature sensor (sensor position indicated by the arrow)
|
| Fig. 3.51. Contact solenoid connector (connector position indicated by the arrow)
|
Click on the tab seal pin (Fig. 3.51) solenoid valve and press inwards. Remove the hydraulic unit, taking care that it does not fell the manual shift valve.
| Fig. 3.52. The adjusting screw of the valve controller
|
Turn the adjusting screw (Fig. 3.52), the valve controller to set the desired line pressure (the pressure in the brake mode Kick-down). By rotating the screw clockwise the pressure is reduced, while rotating counter-clockwise - increases. The pressure should be 8,77-9,18 kg / cm 2. Make sure you have correctly installed and O-ring hydraulic unit. Replace the O-ring connector solenoid valve.
| Fig. 3.53. Installing sump solenoid valve connector (arrow shows the position of the slot connector housing)
|
Install the hydraulic unit on the transmission housing, then insert into the crankcase solenoid connector (Fig. 3.53) so that the groove of the connector housing is in the position shown by the arrow.
NOTE The following describes how to adjust the downward pressure in the absence of the diagnostic tool HI-SCAN. |
Make sure that the wires are not pinched. Tighten the hydraulic block torque 10-12 Nm. Install the oil filter. Install sump with a new seal.
NOTE Rated downward pressure of (4,2 + 0,22) kg / cm 2. When adjusting downward pressure set the average value of the specified limit. Changing the oil pressure for each turn of the adjusting screw is 0.22 kgf / cm 2. |
Fill the gearbox housing required amount of oil for automatic transmissions. Check the oil pressure and adjust it if necessary.
A WARNING This adjustment is carried out at an oil temperature of 80-90 ?� C. If the adjustment is performed at a temperature above the specified pressure at idle the engine falls and correctly adjust the pressure may not be possible. |
Adjustable down pressure Remove items until the oil filter as when adjusting the line pressure. To remove the hydraulic unit is not required. Set the adjusting screw at the bottom of the hydraulic unit required downward pressure. ?????? ?????�?�?�?????? ???�?????�???????????�???????? ???????�?� ???? ?�?�?????????? ???�???�?�???� ?????????�?�???�?�?� ???�???�?�?????� ?????�???????�?�?�????, ?????? ?????�?�?�?????? ???????�???? ?�?�?????????? ???�???�?�???? - ?????�???�???�?�?�?�. ?????�?�?????????�?� ???�???�?????�?? ?�???�???�?? ?? ???�???�?????�?? ???????????? ?�?�?? ?�?�, ???�?? ?? ?????? ???�?????�???????????� ???�???�?�?????? ?? ???�???????�???�?�??. ?????????�?????�?� ???�???�?�?????� ?? ?????? ???�???�?�?????????????�?? ???�???�?????�?????????�?� ?�????. ?�?�???�???� ???�?�???????????? ???�?�???????�?� ???�?�???? ?????�?�?�???�???�???�?�?� ???�?????�?????????�?� ???�?� ?????????????� ?????�?�???� ???� ?????????�???? ???�???�???�?�.
| Fig. 3.54. ?�?�???????�???�?�?????� ???�?�???????????? ???�?�???????�?� ???�?�???? ?????�?�?�???�???�???�?�?� ???�?? ?�?�?????? ?? ?????�?????? ???�????????
|
???????????�?� ???�?�???????? ???�?�???????????? ???�?�?� ( ??????. 3.54 ) ???�???�???�?????? ?? ???�?????????? ???�???�?�??. ???????�???????? (09431-21200) ?�?�?????�?????????�?� ???????�?? ???�?�???????? ???�?�???????????? ???�?�?� ?????�?�?�???�???�???�?�?� ?? ?????�?�???? ???�???�?�???� ?????????�???? ???�???�???�?�. ???�???�?????�?� ?�???�???????????????????????� ???�???�?? ???� ?????�???�???????�???? ???????????? ???�?�?????????�. ?�?�???�???� ???�?�???�?????????????? ?�?�?????� ???????�???�?�?????? (?�?�??) ?????????�?�?�?�?�?? ?? ?�???�???????????????�??
| Fig. 3.55. ?�?�?�???�?????????�?? ?�?�???? ???????�???�?�?????? (?�?�??) ?????????�?�?�?�?�?? ?? ?�???�???????????????�??
|
?�?�?? ?????????�?�?�?�?�?? ?? ?�???�???????????????�?? ( ??????. 3.55 ) ???�???????�???�?�?? ?????? ???�???�?�???? ???????�???????? ???? ???�?????????� ?????????�?�?�?? (???�?? ???�???�?�???? ?�?????????�?�).
???????�???� ?? ?????�?�?????????� ?�???�?????�?�???�?�???????? ?????????�???? ???�???�???�?� Withdrawal ???�?????�?????????�?� ?????????????� ???� ?�???????????�???�?????????? ?�?�?�?�???�?? ?? ???????????�?� ?�?�?�?�???�??. ???????????�?� ?????�???? ?�???????????�???�?????????? ?�?�?�?�???�??. ???????????�?� ???????????�?�???? ?????�???? ?�???????????�???�?????????? ?�?�?�?�???�??. ???????????�?� ???????????? ?????�?????????????? ?�???�???�???�. One of the three bolts located at the bottom of the upper cover of the casing. Remove the air filter bracket.
| Fig. 3.56. Connector selector switch
|
| Fig. 3.57. Connectors solenoid valve and the oil temperature sensor
|
Disconnect the solenoid valve and the oil temperature sensor (Fig. 3.57)
| Fig. 3.58. Removal of a lock pin control cable selector
|
| Fig. 3.59. Oil filler tube
|
Remove the locking plate control cable selector.
| Fig. 3.60. Oil cooler hoses: 1 - feed hose; 2 - outlet hose
|
Disconnect the flexible shaft drive speedometer. Remove the wheel. Remove the starter.
| Fig. 3.61. The top bolt transmission to the engine
|
Remove the upper bolt transmission to the engine (Fig. 3.61). Lift the car and remove the brake caliper. Disconnect the tie rod.
NOTE When installing the device Make sure not to damage the hook of the top cover of the housing. |
| Fig. 3.62. Oil drain plug
|
Remove the oil drain plug and drain the oil from the gearbox (Fig. 3.62).
| Fig. 3.63. Removing the side cover gearbox
|
Remove the wheel speed sensor and unscrew the bolt knuckle. Remove the drive shaft and remove the left wheel hub nut. Install yoke for hanging the engine when removing and installing transmission (catalog number spare parts and accessories 09200-38001). Fix the engine for Traverse.
A WARNING If the motor is first set torque converter, it may be damaged oil seal from the gearbox. Therefore, you must first connect the torque converter transmission. When installing the support bracket equalizer Avoid crushing the elastic cushion, which can cause vibration when the engine is idling. |
Unscrew Transmission Mount:
| Fig. 3.64. Bolts Transmission Mount to the body on the left
|
| Fig. 3.65. Bolts Transmission Mount to the body from the top
|
| Fig. 3.66. Bolt elastic support transmission
|
Remove the rear mounting bracket gearbox, after raising the car.
| Fig. 3.67. Mount converter housing cap
|
| Fig. 3.68. Cover bolts torque converter
|
| Fig. 3.69. Bolt cylinder cover
|
Establish a jack under the gearbox.
| Fig. 3.70. The lower bolts transmission to the engine
|
Remove the lower bolts of a transmission to the engine (Fig. 3.70). Remove the gearbox. Setting Dock gearbox with torque converter to the engine, its fastening screw bolts and tighten them. Set the selector control cable and adjust it as follows: a) set the selector lever and selector switch in position , and connect the control cable selector; b) connect the cable to the bracket suspension transmission and set the stopper so that it touches the rope; c) take up the slack rope rotation of the nut, and then check the smooth movement of the selector lever; d) check the cable adjustment.
The drive gear
| Fig. 3.71. Cables Drive gear: 1 - control cable selector; 2 - a cable lock selector lever
|
| Fig. 3.72. Drive gear: 1 - control cable selector; 2 - the bottom casing of the index; 3 - the top casing of the index; 4 - the handle of the selector lever; 5 - pin selector lever; 6 - an arm of the selector lever; 7 - gear selector lever lock; 8 - Index; 9 - slider; 10 - a cable lock selector lever
|
Withdrawal
| Fig. 3.73. Removing the center console
|
| Fig. 3.74. The locking pin control cable selector
|
| Fig. 3.75. Removing the control cable selector
|
Disconnect the control cable selector by releasing it with a screwdriver (Fig. 3.75).
| Fig. 3.76. Cable lock selector lever
|
Disconnect the cable from the selector lever lock locking cam (Fig. 3.76).
| Fig. 3.77. Bolt rope selector lever lock
|
Remove the bolt rope locking the selector lever (Fig. 3.77).
| Fig. 3.78. Pin pointer movement mode
|
| Fig. 3.79. Bracket bolts selector lever
|
| Fig. 3.80. Bolts cover of a cable to the bottom of the instrument panel
|
Remove the cable by loosening the bolts of his shell to the bottom of the instrument panel (Fig. 3.80). Remove button selector lever handle by undoing the screws securing it, press the up button, and then click on it. Technical condition Check the following: - Retainer for wear; - Bushing for wear or damage; - Spring for damage or weakening; - For wear on the pin end of the rod of the selector lever.
A WARNING After each removal of self-locking nuts must be replaced. |
Installing the drive gear is carried out in reverse order.
| 
