Tip & How-To about Hyundai Tiburon

2004 Hyundai Tiburon Clutch.

First you need to remove the Transaxle.

Manual Transaxle System REMOVAL

1. Remove the engine cover.
2. Remove the battery terminal.
3. Remove the air duct.
4. Remove the battery tray.
5. Remove the air cleaner.
(1) Upper
(2) Lower
6. Remove the back-up lamp switch.
7. After removing the CKP sensor, O2 sensor and oil pressure switch wiring bracket, separate the connectors.
8. Remove the brake fluid leveling sensor connector.
9. Remove the speedometer driven gear connector.
10. Remove the clutch release cylinder mounting bolt.
11. Remove the cotter pin of the shift cable (transaxle side).
12. Remove the cotter pin of the select cable. (transaxle side)
13. Remove the clip of the shift cable (transaxle side).
14. Remove the clip of the select cable (transaxle side).
15. Separate the steering column shaft joint.
16. Separate the power steering oil pump hose.
Be careful not to leak after separating.
17. Separate the hose after removing the clip of the power steering return hose.
18. Remove the upper connecting transaxle bolt.
19. Separate the start motor.
20. Install the engine support fixture.
21. After removing the tire, remove the caliper.
22. Remove the transaxle side cover.
23. Remove the transaxle side under cover.
24. Separate the tie rod end.
25. Remove the wheel speed sensor and the knuckle mounting bolt.
26. Drain the oil.
27. Remove the transaxle mounting bracket.
(1) Insulator bolt
(2) Body side mounting bolt (Upper)
(3) Body side mounting bolt (Side)
(4) Transaxle side mounting bolt.
28. Remove the front roll stopper.
(1) Insulator bolt
(2) Stopper bolt (Upper)
(3) Stopper bolt (Lower)
29. Remove the rear roll stopper.
(1) Insulator bolt
(2) Stopper bolt
30. Remove the drive shaft.
31. Remove the front muffler.
32. Remove the sub frame mounting bolt.
33. Install the transaxle jack.
34. Remove the transaxle lower mounting bolt to the engine.
35. Remove the transaxle assembly.

INSTALLATION
Installation is the reverse of the removal.

Then inspect and replace the clutch place and pressure plate.

INSTALLATION
1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of the clutch release fork assembly.
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and judder.
2. Apply multipurpose grease into the groove of the release bearing.
3. Apply multipurpose grease to the clutch release lever fulcrum contact surface of the clutch release fork assembly.
4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make certain that all oil or grease has been removed.
5. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.
6. Using the special tool, install the clutch disc to the flywheel. When installing the clutch disc, be sure that the surface having the manufactures stamp is towards the pressure plate side.
7. Install the the clutch cover assembly onto the flywheel and install the six (6) bolts through the clutch cover into the flywheel.
8. Tighten the bolts by one or two turns at a time, in succession, to avoid bending the cover flange.
If a special tool is not available, tighten the bolt temporarily and then torque to specification in diagonal torquing sequence indicated below.
TIGHTENING TORQUE
Single mass flywheel:
15~22 N·m (150~220 kg·cm, 11~16 lb·ft)
Dual mass flywheel:
20~27 N·m (200~270 kg·cm, 14~19 lb·ft)
9. Remove the special tool.
10. Install the transaxle. (Refer to GROUP - Manual Transaxle Assembly)
11. Adjust the clutch pedal free-play. (See CH-6)
INSPECTION
1. Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the limit.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
CLUTCH DISC
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out of specification
3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
CLUTCH RELEASE BEARING
The release bearing is packed with grease. Do not use cleaning solvent or oil.
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
INSTALLATION
Installation is the reverse of the removal.
Then remove pressure plate and Clutch plate.

1. Insert the special tool (that came with your clutch kit) in the clutch disc to prevent the disc from falling.
2. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.
3. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

Posted by on

Cars & Trucks Logo

Related Topics:

Related Questions:

1 Answer

bad slave cylinder on 08 jeep patriot


old post.
what engine.?
08 patriot.
why not login to alldata.com and read it, its all there.

excerpts from top 3 online FSM pages.

  1. Remove the transaxle from the vehicle. Refer to Manual Transaxle Assembly, removal & installation.
  2. Disconnect the clutch hydraulic line (6) from the bleeder assembly (2).
  3. Disconnect and remove the bleeder assembly (2) from the clutch slave cylinder (3).
  4. Remove the slave cylinder-to-clutch bell housing bolts (4) and remove the slave cylinder (3) from the transaxle.
so ast step 1, you then turn to that page.
and see
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the splash shields and drain the transaxle fluid.
  3. Disconnect the negative battery cable.
  4. Remove the engine appearance cover.
  5. Remove the air intake assembly.
  6. Unplug the speed sensor connector.
  7. Disconnect the back-up lamp switch.
  8. Remove the shift cables from the bracket clips.
  9. Disconnect the shift selector and crossover cable from the levers. Remove the cables and secure them out of the way.
  10. Remove the slave cylinder hose from the bracket.
  11. Remove the air inlet tube from the throttle body.
  12. Remove the throttle body support bracket.
  13. Remove the upper bell housing bolts.
  14. Remove the starter mounting bolts and secure the starter out of the way.
  15. Support the transaxle with a suitable jack.
  16. Loosen the left-upper transaxle mount through-bolt.
  17. Remove the transaxle mount
  18. Before servicing the vehicle, refer to the Precautions Section.
  19. bolts.
for total of 35 steps.
RTM

Feb 04, 2014 | Jeep Patriot Cars & Trucks

1 Answer

1984 dodge charger. how to i get to the starter



Starter - REMOVAL & INSTALLATION
The starter is an overrunning clutch drive type with a solenoid mounted on the starter motor. Six different type starters are used on these models. Two each are built by Nippondenso, Bosch and Mitsubishi for manual and automatic transaxle applications. Removal and installation procedures are the same for all units. Some early production models may experience starter motor damage due to improper fit of the upper and lower steering column shrouds. Irregularities in the mating surface of the key cylinder area may cause the ignition key to bind, causing the starter to be continuously engaged. The condition can be corrected by loosening the shroud cover screws about 1 1 / 2 turns.
If loosening the screws does not solve the problem, the covers will have to be replaced with new parts, which are available only in black and must be painted to match interior trim.



  1. Disconnect the negative battery cable.
  2. If equipped, remove the heat shield.
  3. On the 2.2L loosen the air pump tube at the exhaust manifold, then swivel the bracket away from the starter.
  4. Remove the wires from the starter and solenoid.
  5. Support the starter, remove the bolts and lift the unit out from the flywheel housing.
  6. Installation is the reverse of removal.
22281f5.jpg

Fig. 1 Starter mounting on the 1.6L engine (click for zoom)

50cdf32.jpg

Fig. 2 Mounting for the 1.7L engine with A-412 manual transaxle

4252200.jpg

Fig. 3 Mounting on the 1.7L engine with the A-404 automatic transaxle

08554c3.jpg

Fig. 4 Mounting for the 1.7L A-460 manual transaxle and the 2.2L manual or automatic transaxle




Hope this help; remember comment and rated this.

Aug 03, 2010 | 1984 Dodge Ramcharger

1 Answer

how to replace starter


Check this procedure for Starter - REMOVAL & INSTALLATION...

2.0L Engine

02f9598.jpg

Fig. 3: Remove the three starter mounting bolts

d4f8fd2.jpg

Fig. 4: Carefully lower the starter out of the vehicle
  1. Disconnect the negative battery cable.
  2. Remove air intake resonators.
  3. Remove starter motor upper mounting bolts.
  4. Raise and support the vehicle.
  5. Remove the nuts on the starter terminals and remove the cables from the terminals.
  6. Remove the two starter lower retaining bolts and remove the starter.
To install:
  1. Place the starter into position and tighten the 2 lower retaining bolts to 15-20 ft. lbs (20-27 Nm).
  2. Place the starter cables onto the terminals and tighten the retaining nuts to 80-124 inch lbs. (5-7 Nm).
  3. Lower the vehicle.
  4. Install and tighten the upper retaining bolt to 15-20 ft. lbs (20-27 Nm).
  5. Install the air intake resonators.
  6. Connect the negative battery cable.

2.5L Engine

6f17117.jpg

Fig. 5: Starter mounting-2.5L engine
  1. Disconnect the negative battery cable.
  2. Remove the engine air cleaner assembly.
  3. Remove the fuel feed and return lines from the support bracket located on the accelerator cable bracket, and remove the fuel line bracket.
  4. On vehicles equipped with a automatic transaxle, remove the gear selector and the gear shift cable bracket from the transaxle.
  5. Remove the air cleaner support bracket from the engine and transaxle mount.
  6. Remove the nuts on the starter terminals and remove the cables from the terminals.
  7. Remove the starter motor-to-transaxle case retaining bolt at the rear of the starter.
  8. Remove the two starter retaining bolts and carefully lift the starter from the transaxle case while disengaging the alignment pins.
To install:
  1. Position the starter onto the alignment pins and onto the transaxle case.
  2. Install the two starter retaining bolts and the rear retaining bolt and tighten them to 15-21 ft. lbs. (21-29 Nm).
  3. Place the starter cables onto the terminals and tighten the retaining nuts to 80-124 inch lbs. (5-7 Nm).
  4. Install the air cleaner support bracket.
  5. If removed, install the gear shift selector and bracket.
  6. Install the fuel line bracket and install the fuel lines in the bracket.
  7. Install the air cleaner assembly.
  8. Connect the negative battery cable.

Hope helps (remember comment and rated this).

Jul 16, 2010 | 1998 Mercury Mystique

1 Answer

remove gear box


This is a big job, and I list what to do, but I wou9ld also recommend you purchase a good manual, or go to alldatadiy site to purchase on line access to diagrams, info etc (great site) 1. disconnect battery ground cable @ battery and trans. case, unlock steering column, put trans. in neutral 2.disconnect back u light switch wires + black and white wire from starter solenoid 3remove air cleaner assembly 4.remove power steering speed sensor from the transaxle w/out removing the power steering hose 5remove the shift cable and the select cable from the top cover of the transaxle.Remove the mounting bolt from the cable stay. Be sure not to bend or kink the cable more than necessary. Remove both cables and the stay together. 6 Remove upper transaxle mounting bracket, remove the 4 transaxle to block attachment bolts that must be removed from the engine compartment. 7 Raise and support the vehicle safely. Remove both front wheels and splash shield 8 Drain the trans oil, remove clutch save cylinder. The cyl may be moved out of the way w/out disconnecting the hose 9 remove the center beam, remove the right radius rod completely, remove the right and left shafts. 10 remove the engine stiffener, remove the clutch cover, support the transaxle w/ a trans jack 11 remover the 3 lower bolts from the rear engine mounting bracket. Loosen but do not remove the top bolt. This bolt will support the weight o f the engine. 12 remove the 2 remaining engine to transaxle bolts. 13 with transaxle on a transmission jack disengage the input shaft from the clutch disc and lower the transaxle out of the vehicle. DO NOT ALLOW THE TRANSAXLE to hang on the input shaft. Once removal begins, remove it completely from the engine. Good luck, and please rate this, it took a while to get it down!

Nov 16, 2009 | 1991 Honda Prelude

1 Answer

replacing starter for 2000 elantra gls


Verbatim from Haynes manual:

1. Disconnect the cable from the negative terminal of the battery.
2. If your working on a 2000 or earlier model, remove the air intake duct and the air cleaner assembly.
3. If your working on a 2001 or later model, detach the shift cables(s) from the transaxle.
4. Disconnect the speedometer cable from the transaxle.
5. Unscrew the nut and disconnect the battery cable from the starter motor, then disconnect the wiring from the solenoid.
6. Remove the starter motor mounting bolts, supporting the starter motor as the bolts are removed, and remove the starter motor.
7. Installation is the reverse of removal. Tighter the starter mounting bolts to 20-25 foot pounds.

Oct 11, 2008 | 2000 Hyundai Elantra

Not finding what you are looking for?

3,562 people viewed this tip

Ask a Question

Usually answered in minutes!

Top Hyundai Experts

yadayada
yadayada

Level 3 Expert

74945 Answers

Colin Stickland
Colin Stickland

Level 3 Expert

22095 Answers

Jeff Turcotte
Jeff Turcotte

Level 3 Expert

7697 Answers

Are you a Hyundai Expert? Answer questions, earn points and help others

Answer questions

Loading...