Manual Transaxle Case: Reassembly

Install the differential oil seal using special tool (09431-2C000).

Fig 1: Installing Differential Oil Seal
Courtesy of HYUNDAI MOTOR CO.
Calculate the thickness N dimension of adjusting shim as it shows below, keeping end play of differential side bearing as below dimension.
NOTE: Select one or two pieces of differential side bearing adjusting shim.

End play (mm): 0.15-0.21

Shim thickness N = N1 - N2 + end play

Fig 2: Identifying Adjusting Shim & Outer Race
Courtesy of HYUNDAI MOTOR CO.

DIFFERENTIAL SIDE BEARING ADJUSTING SHIM
Thickness (mm)
1. 0.48
2. 0.52
3. 0.56
4. 0.60
5. 0.64
6. 0.68
7. 0.72
8. 0.76
9. 0.80
10. 0.84
11. 0.88
12. 0.92
Fig 3: Measuring "N1" Measurement
Courtesy of HYUNDAI MOTOR CO.

Fig 4: Measuring "N2" Measurement
Courtesy of HYUNDAI MOTOR CO.
Install the differential side bearing adjusting shim and the differential side bearing outer race using special tool (09431-2C300).

Fig 5: Installing Differential Side Bearing Adjusting Shim & Differential Side Bearing Outer Race
Courtesy of HYUNDAI MOTOR CO.
Assemble the oil gutter and the baffle plate.
At this time, put the grease on fixing part.

Fig 6: Installing Baffle Plate & Oil Gutter
Courtesy of HYUNDAI MOTOR CO.
Spread the seal on the surface of the case and the housing.
At that time, spread inside the bolt hole.

Fig 7: Installing Spread Seal
Courtesy of HYUNDAI MOTOR CO.
Check the output shaft snap ring and shim of transaxle case side. Ensure that the snap ring gap comes to bore plug hole.
Hold a case with your both hands, cover the housing side.
If it is inserted excessively, it may damage.

Fig 8: Installing Case Assembly
Courtesy of HYUNDAI MOTOR CO.
There should now be about a 4 mm gap space between the case and housing.

Fig 9: Identifying 4 mm Gap
Courtesy of HYUNDAI MOTOR CO.
Extend the snap ring of case side, then the case fall down by own weight.
So there is no space between case and housing.

Fig 10: Identifying Snap Ring
Courtesy of HYUNDAI MOTOR CO.
Tighten the case and the bolt of the housing.

Fig 11: Identifying Case Bolts
Courtesy of HYUNDAI MOTOR CO.
Install the control shaft assembly.

Fig 12: Installing Control Shaft Assembly
Courtesy of HYUNDAI MOTOR CO.
Put the select stopper bolt in neutral position.
Put in the shift check.
Fix the check ball, and the spring by the bolt. (There are 2 places)

Fig 13: Identifying Check Ball & Spring Bolt
Courtesy of HYUNDAI MOTOR CO.
Shift to the 2nd gear, and keep lift the output shaft, and fix the snap ring of output shaft bearing.
Put in the bore plug.

Fig 14: Identifying Bore Plug & Control Shaft
Courtesy of HYUNDAI MOTOR CO.