Questioninformation on removing and replacing a clutch on a november 1992 hyundai excel please thanks wayne
AnswerHi, Wayne. It's been awhile since I've done one of these, so I'll first give you the address to the Hyundai website where you can view the service manuals, among other useful information.
Go to www.hmaservice.com and register for a free account. The site will require Internet Explorer to operate.
Below are the steps as best I can recall. Try to make sure each passes a believability test so you don't get yourself caught somewhere you'd rather not be.
1. Disconnect the negative battery terminal.
2. Disconnect the air flow sensor electrical connector.
3. Loosen the clamp holding the air intake bellows onto the throttle body.
4. Disconnect the breather hose from the air bellows.
5. Remove the three 10mm bolts holding the air cleaner in place and remove the air cleaner and intake bellows as an assembly.
6. Disconnect the back-up lamp switch electrical connector.
7. Disconnect the shift cables from the transmission. (I believe you'll need to unclip the cable ends and either unbolt the cable bracket or unclip the cables from the bracket).
8. Disconnect the speedometer cable from the transmission.
9. Unbolt the slave cylinder from the transmission and move out of the way as necessary. Make sure the hydraulic lines and hoses are not attached to the transmission. (You may wish to do this step later if it's easier from underneath the car).
10. Remove the two 14mm bolts holding the starter in place.
11. Remove the two 14mm(?) bolts holding the top of the transmission to the engine.
12. Remove the 10mm bolt holding the engine back plate to the transmission.
13. Support the transmission with a floor jack.
14. Remove the three (two?) 17mm bolts holding the transmission to the mount.
15. Remove the floor jack.
16. Remove the splash shields.
17. Remove the 24mm transmission drain plug and catch the old oil in a suitable container.
18. Remove the 17mm fill plug from the transmission.
19. Reinstall the 24mm drain plug.
20. Remove the 17mm bolts and nuts attaching the ball joints to the control arms.
21. Remove the 32mm nuts holding the axles in the wheel hubs.
22. Remove the axles.
23. Remove the 10mm bolt(s) attaching the flywheel cover to the transmission.
24. Remove the two 14mm bolts attaching the lower portion of the transmission to the engine.
25. Remove the transmission. (Transmission is heavy. Do not allow it to drop onto you. Severe injury could result.)
26. Remove the six 12mm bolts holding the clutch cover in place.
27. Remove the clutch cover and clutch disc.
28. Inspect the flywheel. Remove if necessary and resurface or replace.
29. Using a clutch alignment tool, place the new clutch into position, taking care to mount the correct side toward the engine.
30. Install the new clutch cover and six 12mm bolts.
31. Remove the old throwout bearing from the transmission.
32. Install a new throwout bearing.
33. Install the transmission onto the engine and secure in place with the two lower 14mm bolts.
34. Reattach the flywheel cover to the transmission with the two 10mm bolts.
35. Reinstall the axles.
36. Install the 32mm axle nuts and use new cotter pins to lock in place.
37. Reattach the ball joints to the control arms using the 17mm bolts and nuts.
38. Install new gear oil into the transmission.
39. Install the 17mm fill plug.
40. Install the splash shields.
41. Support the transmission with a floor jack.
42. Reattach the transmission to the mount using the three (two?) 17mm bolts.
43. Reinstall the two upper 14mm(?) bolts attaching the upper transmission to the engine.
44. Install the 10mm bolt holding the rear engine plate to the transmission.
45. Reattach the starter and engine ground wire using the two 14mm bolts.
46. Reinstall the slave cylinder.
47. Reattach the speedometer cable.
48. Reinstall the shift cables.
49. Reconnect the back-up lamp switch.
50. Reinstall the air cleaner and bellows assembly and secure.
51. Reattach the breather hose.
52. Reconnect the air flow sensor.
53. Reconnect the negative battery terminal.
