In detail: DIY solaris manual transmission repair from a real master for the site my.housecope.com.
We remove the gearbox for repair or replacement, replacement of discs and clutch slave cylinder, as well as when dismantling the engine. We install the car on a viewing ditch or overpass. Remove the engine control unit (see Removing the Hyundai Solaris electronic engine control unit). Remove the storage battery pad (see Removing the Hyundai Solaris ABS unit). Remove the air filter housing (see Removing the Hyundai Solaris air filter). Remove the front wheel drives (see Removing the front wheel drives of the Hyundai Solaris). Remove the starter (see Removing and checking the Hyundai Solaris starter). Disconnect the ends of the engagement and gear selection cables from the gear shift levers (see Replacing the cables of the Hyundai Solaris gearbox control mechanism).
Pressing the latch, disconnect the wiring block from the reversing light switch.
Squeezing the clips of the wiring harness holder, remove the holder from the hole in the gearbox bracket.
Using the "12" head, we unscrew the three bolts securing the bracket for the transmission control cables ...
… And move the bracket with the cables away from the gearbox. Remove the vehicle speed sensor from the gearbox (see Removing the Hyundai Solaris vehicle speed sensor). We unscrew the two bolts securing the clutch slave cylinder (see Removing the clutch slave cylinder for the Hyundai Solaris).
With a spanner wrench "12" we unscrew the bolt securing the bracket for the hydraulic hose of the clutch release ...
… And move it away from the gearbox along with the clutch slave cylinder.
Video (click to play).
Using the "12" head, unscrew the bolt securing the tip of the "ground" wire.
Remove the heat shield of the inner hinge of the right wheel drive.
... with the "12" head we unscrew the four bolts securing the air duct for blowing the inner hinge of the right wheel drive ...
We install adjustable stops under the engine and gearbox.
Using the "17" head, unscrew the three bolts securing the left engine support bracket to the gearbox housing.
Using the "14" head, unscrew the two upper bolts securing the gearbox to the engine block.
Using the "14" head, unscrew the four bolts securing the gearbox to the engine oil pan and one bolt to the cylinder block.
The location of the lower bolts securing the gearbox to the engine.
We remove the gearbox from the engine, removing the input shaft from the hub of the clutch disc, and remove the gearbox. When installing the box on the engine, it is necessary to direct the input shaft so that the splines of the shaft mesh with the splines of the clutch disc. For correct centering of the gearbox, turn it so that the guide bushings pressed into the cylinder block align with the holes in the gearbox. After making sure that the gearbox is installed correctly, tighten the bolts and tighten them to the prescribed torque (see Appendices). Further installation of the gearbox is carried out in the reverse order. Fill the transmission oil into the gearbox (see Checking the oil level in the Hyundai Solaris manual gearbox). We connect the cables to the gearshift levers (see Replacing the cables of the Hyundai Solaris gearbox control mechanism).
The need to remove the control mechanism of a manual transmission arises in cases of damage and malfunction. Removing the lever 1. Disassemble and remove the floor tunnel panels. 2. Unscrew the handle together with the decorative cover and frame. We do it against.
The maintenance schedule does not provide for an oil change in the Hyundai Solaris manual transmission, the oil is designed for the entire service life. However, in cases of repair, it is often necessary to drain the oil. In addition, if the car is operated in.
Checking the oil level, in accordance with the technical regulations for servicing the manual transmission Hyundai Solaris, must be performed every 60 thousand kilometers. It is also necessary to check the oil level in cases of oil leaks. We measure the oil level.
Removing the manual transmission Removing the manual transmission is necessary when replacing the clutch disc or if the gearbox mechanism itself requires repair. The removal process is carried out on an overpass or inspection pit. 1. Remove the drain plug and drain into a suitable one.
The main malfunctions, for the elimination of which it is necessary to remove the manual transmission from the car:
increased (compared to the usual) noise;
difficult gear shifting;
spontaneous shutdown or clear inclusion of gears;
oil leaks through seals and gaskets.
In addition, the gearbox is removed to replace the clutch, flywheel and rear oil seal of the engine crankshaft.
The work on removing and installing the gearbox is very time consuming, therefore, be sure to first make sure that its malfunctions are not caused by other reasons (insufficient oil level, defects in the clutch release drive, loosening of the gearbox fastening, etc.).
The gearbox is quite heavy and uncomfortable to hold, so we recommend removing it with an assistant.
You will need: socket wrenches "for 10", "for 12", "for 14", "for 17", a mounting blade, pliers.
1. Disconnect the wire from the negative terminal of the storage battery.
4. Disconnect the harness block from the electronic engine control unit (see Removing and installing the electronic engine control unit).
5. Remove the bolts securing the bracket of the electronic unit to the shelf of the storage battery.
7. Remove the ECM assembly with bracket.
8. Remove the five bolts securing the battery shelf.
10. Remove the air inlet sleeve and air filter housing assembly (see Removing and Installing Air Filter Housing).
11. Remove the wiring harness bracket securing bolt.
12.… and move it to the side with the wiring harness.
13. Depress the reversing light switch harness block retainer and disconnect the block from the switch.
14. Use a screwdriver to pry the cable end cotter pin ...
15. ... and remove it from the hole in the shaft of the gear lever.
17. ... and the tip of the cable from the shaft of the gear lever.
18. Remove the cotter pin securing the end of the cable from the hole in the shaft of the selector lever.
nineteen. . and remove the cable end from the shaft of the select lever.
20. Remove the ends of the sheaths of the cables from the sockets of the bracket on the gearbox and take the gearbox control cables to the side.
21. Remove the three bolts of the transmission control cable bracket.
23. Using a screwdriver, remove the retainer.
24. ... and disconnect the harness block from the speed sensor.
25. Depressing the retainer, disconnect the harness block from the crankshaft position sensor.
26. Remove the bolt securing the tip of the "ground" wire ...
27. ... and take the wire aside.
28. Remove the bolt securing the clutch pipe bracket to the gearbox housing.
29. Remove the two screws securing the slave cylinder.
thirty.Move the slave cylinder with bracket and pipe to the side and secure it to the body, for example with wire.
34. Remove the three bolts securing the transmission to the power unit suspension support bracket.
35. Remove the two transmission upper mounting bolts.
Engine coolant hoses removed for clarity.
36. Install reliable supports under the gearbox and engine.
37. Remove the rear suspension support of the power unit (see Replacing the suspension mounts of the power unit).
38. Remove the five lower transmission mounting bolts.
39. Supporting the transmission, remove the support from under it.
40. Move the gearbox back until the input shaft comes out of the clutch disc hub ...
41.… and carefully remove the transmission from the vehicle.
When removing the transmission, do not rest the end of the input shaft against the diaphragm spring petals, so as not to deform them.
42. Install the transmission and all removed parts and assemblies in the reverse order to removal.
Before installing the gearbox, we recommend lubricating the input shaft splines with a thin layer of refractory grease.
Check with a special mandrel how the clutch disc is centered (see Removing and installing the clutch).
The exact mileage of a car in which clutch problems occur is difficult to identify. In most cases, this happens after the official warranty from an authorized dealer expires. The replacement can be done by yourself if you have experience in servicing the car and the appropriate tool.
The new clutch has minimal wear, which is why little effort is required to press the pedal. Over time, the disc wears out (the friction pads become thinner) the petals go to the side, respectively, and the fork changes its position. When you press the clutch pedal, you have to apply more force.
Before changing the clutch on the Solaris, make sure that this particular unit is out of order. The first sign that you need to prepare for the repair is the difficulty in shifting gears. Also pay attention to the following symptoms:
the clutch pedal began to be pressed with great effort;
"Grab" the grip start at the very bottom;
when shifting 3rd or 5th gear, the clutch is engaged;
twitching is observed when shifting gears.
Therefore, before purchasing the kit and starting to replace the Solaris clutch, make sure that all units are in full serviceability, that there is no airing of the hydraulic system. If there is a suspicious crunch when changing gears, it may be necessary to replace the master cylinder or the working cylinder.
A separate case when, when shifting, slipping occurs due to the ingress of oil on the clutch disc. Signs of this problem may include:
traces of oil in the lower part in the area of the gearbox and engine connection;
increased engine oil consumption.
The reason for this may be a gearbox malfunction. Due to the destruction of the input shaft seal, oil from the engine enters the inside of the box, where the disc becomes oiled. In this case, before changing the clutch, it is necessary to repair the gearbox.
Knowing that the factory-installed Solaris clutch resource is relatively small, the manufacturer uses an improved design in modern models. When purchasing a new kit, prioritize OE parts with an 18 petal basket. In the factory configuration, a part with 12 petals is most often present. Also replace the entire kit, which includes:
clutch disc;
clutch basket;
release bearing;
clutch fork.
Replacing the clutch on Solaris with your own hands takes time, as well as performing a large amount of dismantling work associated with disassembling the chassis.Replacement of some elements of electrical equipment will be required. If necessary, with the installation of a new clutch, you can carry out preventive work with the starter, elements of the consumable parts of the chassis. It would be logical to change the oil in the gearbox.
Position the vehicle on a viewing pit or lift before disassembling. Block the rear wheels and remove the battery. Then remove the protection from the bottom of the motor and remove both front wheels. Drain the oil from the gearbox. If the car is installed on a jack, consider the possibility of jacking up the motor.
Dismantle the ECU.
Disconnect the battery holder.
Dismantle the box with the air filter and pipes.
Remove the starter.
Disconnect from the checkpoint all elements that interfere with its dismantling.
Remove the front wheel drives.
Disconnect the selector and shift cable ends from the shift levers.
Disconnect the reverse gear electrical connector.
Remove the speed sensor from the gearbox.
Dismantle the slave cylinder and hydraulic line.
Remove the bolt holding the ground wire.
Remove the heat shield for the right-hand drive inner joint. Support the engine securely by jacking it up from below.
Remove the left engine mount that connects to the transmission housing.
Disconnect the transmission from the engine block.
Unscrew the 4 bolts connecting the gearbox and the engine oil pan. Move the transmission away from the engine so that the input shaft comes out of the clutch plate hub.
To replace the clutch on the Hyundai Solaris, you must first dismantle the faulty unit. To do this, you need to perform simple operations.
Unscrew the 6 bolts to 12 connecting the flywheel to the clutch basket.
Keep the crankshaft stationary. To do this, use a lever that is inserted into the gap between the flywheel teeth. Place it on a bolt inserted into one of the holes in the engine oil pan.
Remove the clutch pressure plate and clutch disc.
Make sure the pins on the flywheel line up with the holes in the clutch basket.
Install the new driven and pressure discs in reverse order, observing the sides. To do this, use a centering mandrel of the appropriate diameter.
Insert the shank of the arbor into the bore of the crankshaft flange.
Install the bolts. Tighten the opposing bolts one turn in a circle.
Finally tighten the bolts to the required torque.
Remove the centering tip.
When replacing the clutch, it is rational to install a new release bearing. Even if it is in working order and there are no signs of wear. This completes the replacement of the clutch on the Hyundai Solaris. Assemble parts and assemblies in the reverse order, observing the tightening torques of bolts and nuts recommended by the manufacturer.
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However, for a Hyundai owner, do-it-yourself repairs are as necessary as for drivers of other cars. We will help you understand them in accordance with the requirements of the Hyundai Getz repair manual. You can quickly and easily replace the timing belt, spark plugs and ignition coils, brake disc assemblies. When repairing South Korean brand cars, you should take into account the condition of all major components and, if possible, change them on time. A hatchback requires competent replacement of the fuel, air and cabin filters.
Windshield replacement and suspension maintenance also require some experience. The year of foundation of the company is considered. However, for the owner of Hyundai, do-it-yourself repairs are the same necessity as for the drivers of other cars.
A hatchback requires competent replacement of the fuel, air and cabin filters. However, for a Hyundai owner, do-it-yourself repairs are as necessary as for drivers of other cars. The year of foundation of the company is considered to be
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Previous 1 2 3 4 5 Next. The available model range amazes not only the number of models and modifications, but also a wide list of options. Owners of other models will find useful information on these videos: When repairing South Korean cars, you should take into account the condition of all major components and, if possible, change them on time.
