HYUNDAI AERO TOWN D6DA 2010 hộp số sàn INPUT SHART REMOVAL

REMOVAL Remove the rear bearing retainer (1)Remove the bearing retainer mounting bolt (2)Remove the bearing retainer 2.Remove the speedometer sensor(A) Remove the oil seal 4.Remove the speedometer sensor tone wheel 5.Remove the front bearing mounting bolt Remove the front bearing retainer • Oil seal is attached inside the front bearing retainer • Cover(e.g with aluminum foil)the spline of the input shaft so as not to damage the lop of the oil seal when removing retainer 7.Remove the bearing and input shaft 8.Using a retainer ring plier, remove the retainer ring from the input shaft • Be careful with the retainer ring that may pop up while removal 9.Using a press, remove the cylindrical bearing 10 Using a screw driver, remove the retainer ring from the groove of the input shaft, and then remove the roller bearing from the input shaft • Be careful with the retainer ring that may pop up while removal 11 Remove the retainer ring from he output shaft rear bearing • Be careful with the retainer ring that may pop up while removal 12.Remove the rear bearing 13 Attach a jig to the end of the output shaft • If the output shaft assembly is removed from the transmission without jig, the reverse gear will drop from the shaft and possibly result in personal injury 14 Remove the output shaft assembly from the transmission case When removing output shaft assembly, remove the synchronizer ring and the cone of the input shaft gear 15.Remove the jig from the end of output shaft Installation Install output shaft assembly to the transmission case When assembling output shaft, assemble the synchronizer ring and input shaft cone 2.Install the retainer ring to the bearing before installing rear bearing Install the bearing to the output shaft 4.Apply the gear oil to the outer and inner race • Be careful not to damage the inner race surface 5.Install the cylindrical bearing by using press • Be careful not to damage the inner race surface Install the retainer ring(A) 7.Install the cylindrical bearing (1)Apply the gear oil to the bearing (2)Install the spacers at both ends of bearing • If needed, replace the bearing by units of set 8.Install the input shaft assembly 9.Install the oil seal 10 Install the front bearing retainer (1)When installing bearing retainer, align the gasket notch with oil drain hole to assemble the gasket (2)Apply the grease to the oil seal and input shaft (3)Apply the sealer to the both ends of gasket 11 Install the front bearing retainer mounting bolt Tightening torque : 37.24~49Nm(3.8 ~ 5.0 kgf.m, 27.63~36.35lb-ft) • Apply sealing tape or sealer to the bolt(A) thread 12.Install the speedometer sensor tone wheel 13 Install the speedometer drive gear • Be careful not to damage of O-ring and seal lip 14 Install the oil seal When installing the oil seal, check right angle alignment and take care not to damage the seal lip Apply grease to the lip 15.Install the rear bearing retainer Tightening torque : 39.2~49Nm(4~5kgf.m, 29.08~36.35lb-ft) • Apply liquid sealer or sealing tape to the bolt threads • Apply liquid sealer to both sides of the gasket 16 Inspection of the output shaft (1)Inspect the output shaft backlash ITEM REFERENCE LIMIT 1st,reverse gear 0.08~0.16 mm 0.05~0.07mm 2nd, 3rd, 4th gear 0.1~0.2 mm (2)Inspect the end play of gears ITEM REFERENCE 1st, 2nd, 3rd 0.15~0.3 mm 4th gear 0.175~0.475 mm reverse gear 0.20~0.35 mm reverse idle gear 0.15~0.60 mm LIMIT 0.15~0.60 mm 25.Remove the synchronizer key and head • Be careful with the spring that may pop up while removal 26.Remove the compression spring 27.Remove the retainer that fixes the synchronizer ring to gear (3rd , 4th gear) • Be careful with retainer ring that may pop up in removal 28.Remove the synchronizer cone from the gear INSPECTION INSPECTION OF GEAR AND SHAFT Inspect crack and defect of every gear, and replace it if any defect is found 2.Inspect damage and worn-out of input shaft(A) and replace it if and defect is found Inspect damage and worn-out of output shaft(A) and replace it if ant defect is found Synchronizer unit inspection Inspect any damage or worn-out of assembling parts of synchronizer unit If any damage is found, replace the assembling part 2.Inspect any damage or worn-out of the slanted parts and synchronizer cone gear And replace it if any damage is found Measure the clearance between synchronizer ring and the slanted part of synchronizer cone If the measured clearance lies within the service limit, replace the synchronizer ring and cone Assembly standard : 1.2 ~ 1.8 mm Maintenance criteria : 0.2 mm 4.Inspect the contact between synchronizer ring and slanted part of synchronizer cone If the contact area is less than 90%, replace the synchronizer ring and cone Total contact : more than 90% Bearing inspection Inspect any damage or worn-out of cylindrical bearing, and replace if any defect is found 2.Check the needle bearing for any damage or worn-out If any defect is found, replace the bearing Oil seal inspection Check the oil seal for any damage or worn-out If any defect is found, replace the oil seal Speedometer gear inspection Check speedometer drive gear and driven gear If any damage or worn-out is found, replace it REASSEMBLY Install compression spring • Assemble the synchronizer unit 2.Install synchronizer key and head • Be careful with compression spring that may pop up during the assembly Assemble the synchronizer sleeve 4.Install synchronizer cone on the 3rd and 4th gear 5.Fix the gear and synchronizer with the retainer ring • Make sure to align the retainer ring to the groove of gear • Be careful with the retainer ring that may pop out during installation Install spacer and 2nd gear needle roller bearing(A) on output shaft • Insert the spacer to each bearing • Apply the gear oil to each needle roller bearing and gear 7.Install the 2nd gear(A) 8.Assemble the 1st, 2nd synchronizer hub(A) • When assembling hub, place the side with the larger chamfering close to the gear spline face of 1st gear (Chamfering : 1.5 mm) Besides, numbers are marked at the hub side to prevent the mistake in assembly 9.Install the 1st gear bushing Heat the bushing around 85°C with heater and assemble it to the shaft end • Do not touch the heated bushing with hands 10 Install the needle roller bearing(A) for 1st gear 11 Install the 1st gear(A) 12.Install the constant hub 13 Install reverse gear bushing Heat the bushing around 85°C with heater and insert it to the output shaft end • Do not touch the heated bushing with hands 14 Install the needle roller bearing(A) for reverse gear 15.Install the reverse gear(A) 16 Hold the thrust washer with the jig • If output assembly is assembled to transmission without using the jig, reverse gear may drop 17 Install the needle roller bearing and spacer for 3rd gear • Place the spacer between bearings 18 Install the 3rd gear(A) 19 Install the synchronizer unit(A) of 3rd - 4th gear 20.Install the pin(A) 21.Install the 4th gear(A) 22.Install the needle roller bearing(A) for 4th gear 23.Install the bushing for the 4th gear • Align the bushing grooves with pin 24.Install the retainer ring(A) (1)Select the retainer ring (2)Install the retainer ring and make sure to be correctly positioned • Be careful with the retainer ring that may pop out during installation (3)Check the clearance Assembly standard : Following types of retainer rings are available Thickness Color 2.35 mm - 2.45 mm White 2.55 mm Green 2.65 mm Brown • Use only the new retainer rings 25.Install the gear needle roller bearing(A) 26.Install the synchronizer cone(A) 27.Assemble synchronizer unit(A) for 4th - 5th gear 28.Install the retainer ring(A) (1)Select the retainer ring (2)Install the retainer ring and make sure to be correctly positioned • Be careful with the retainer ring that may pop out during installation [...]... up while removal 26.Remove the compression spring 27.Remove the retainer that fixes the synchronizer ring to gear (3rd , 4th gear) • Be careful with retainer ring that may pop up in removal 28.Remove the synchronizer cone from the gear INSPECTION INSPECTION OF GEAR AND SHAFT 1 Inspect crack and defect of every gear, and replace it if any defect is found 2.Inspect damage and worn-out of input shaft(A)... output shaft • Be careful with the retainer ring that may pop up while removal 4.Remove the 4th - 5th synchronizer unit(A) 5.Remove the synchronizer cone(A) 6 Remove the needle roller bearing(A) 7.Remove the retainer ring that fixes the 4th gear bushing to the output shaft • Be careful with the retainer ring that may pop up while removal 8.Remove the 4th gear housing 9.Remove the 4th gear(A) 10 Remove