Hyundai i20 Quiz
MANUAL TRANSMISSION SYSTEM

Manual Transaxle Repair Procedures

In this manual: MANUAL TRANSMISSION SYSTEM
General Information — 17Engine Mechanical System — 79Engine Electrical System — 50Emission Control System — 22Engine/Fuel Control System — 107Clutch System — 27MANUAL TRANSMISSION SYSTEM — 21Drive Shaft and Axle — 18Suspension System — 29Steering System — 21Restraint — 41Braking System — 53Body Work (Interior and Exterior) — 190Body Electrical System — 181Heating, Ventilation and Air Conditioning — 58
26steps
~176min
5/5difficulty
4special tools
0102030405021.616N·mlb·ft
Tightening torque found on this page
Done 0 of 26

DEPOSIT

  1. Remove the air cleaner assembly. (Refer to Engine Mechanical System - "Air Cleaner")
  2. Disconnect the battery and battery tray. (Refer to Engine Electrical System - "Battery".)
  3. Remove the ECM. (Refer to Engine Control System - "ECM".)
  4. Disconnect the back-up light switch connector (A).
  5. Disconnect the neutral switch connector (A).
  6. Remove the transaxle ground cable (A).

    Tightening Torque: 14.7 – 22 N·m

  7. Remove the clutch tube bracket bolt (A).

    Tightening Torque: 14.7 – 22 N·m

  8. Disconnect the shift cable (A) and select cable (B) after removing the retaining clip (C).
  9. Remove the control cable bracket (A) after removing the bolts (B - 3 EA).

    Tightening torque: 14.7 ~ 22 N·m

  10. Remove the upper hood cover. (Refer to Body group - "Upper Cowl Cover")
  11. Install the engine support fixture. (Refer to Special Service Tools; "Engine Mounting Support Member Tool Drawing".)
  12. Using the engine support fixtures (harness No.: 09200-38001 or 09200-3N000, support No.: 09200-2S000), carefully support the engine and transaxle assembly.
  13. Remove the upper transaxle mounting bolts (A - 2 EA) and starter motor bolts (B - 2 EA).

    Tightening Torque: 14.7 – 22 N·m

  14. Remove the dust cover (A).
  15. Remove the transaxle bracket mounting bolts (A).

    Tightening torque: 88.3 ~ 108 N·m

  16. Remove the support (A) from the transaxle.

    Tightening torque: 58.9 ~ 78 N·m

  17. Remove the engine room under cover. (Refer to Engine Mechanical System - "Engine Room Under Cover".)
  18. Separate the assembly from the drive shaft. (Refer to Axle and Propeller Shaft - "Drive Shaft".)
  19. Remove the drive shaft cover (A).
  20. Remove the clutch release cylinder assembly (B) after loosening the bolts (A - 2 EA).

    Tightening Torque: 14.7 – 22 N·m

  21. Loosen the heat exchanger tube mounting bolts (A).
  22. Remove the roll stopper (A) after removing the mounting bolts (B - 2 EA, C - 1 EA). Tightening torque: (B) 49.0 ~ 69 N·m (C) 107.9 ~ 128 N·m
  23. Remove the roll stopper bracket (A).

    Tightening torque: 49.0 ~ 69 N·m

  24. Remove the mounting bolts (A - 3 EA, B - 2 EA) from the bottom of the transaxle and left side cover, then remove the transaxle assembly while supporting it with a jack. Tightening torque: (A) 43 ~ 49 N·m (B) 43 ~ 55 N·m

REMEDY

  1. To install, perform the removal procedure in reverse order.
  2. Add manual transaxle fluid after installing the transaxle. (Refer to Manual Transaxle System - "Transmission Fluid".)

Test yourself

A quick Hyundai i20 quiz: every answer comes with an explanation and a link to the manual page.