Hyundai Getz>> Transmission>> Coupling
General information
Moments of an inhaling of carving connections, N · m
Bolt of fastening of a pedal to an arm..... 25–35
Bolt of fastening of the main cylinder to a pedal arm..... 17–26
Cap nut of fastening of the pipeline..... 13–17
Holder of the pipeline..... 4–6
Bolt of fastening of the working cylinder..... 15–22
Hollow bolt of fastening of the pipeline to the working cylinder..... 25
Bolts of fastening of a casing of coupling..... 15–22
Nut of fastening of a pusher of the main cylinder to a pedal..... 9–14
Nut of fastening of the switch of blocking of ignition..... 8–10

Technical characteristics
Type of a drive of coupling
The hydraulic
Conducted disk of coupling
Dry, diafragmenny
External/internal diameter of a conducted disk, mm
215/145
Coupling casing assembled with a press disk 
With a diafragmenny press spring
Internal diameter:
    working cylinder, mm
    main cylinder, mm

20,64
15,57

Data for checks and adjustments
Type of a drive of coupling
The hydraulic
Thickness of a conducted disk (in a free condition) mm:
   engines 1,3; 1,5 and 1,6 l
   engine of 1,1 l


8,5±0,3
8,0±0,3
Free wheeling of a pedal of coupling, mm
6-13
Height of a pedal of coupling over a floor, mm
160,7
Course of a pedal of coupling, mm
140
Gap between the working cylinder and the piston, mm
0,15
Gap between the main cylinder and the piston, mm
0,15

Applied lubricants
Application place
Name
Surface of contact of a fork with the bearing of switching off of coupling
CASMOLY L9508
Internal surface of the bearing of switching off of coupling
CASMOLY L9508
Mirror of the working cylinder, external surface of the piston and cuff
Brake DOT-3 liquid
or DOT-4
Shlitsa of a conducted disk of coupling
CASMOLY L9508
Mirror of the main cylinder and external surface of the piston
Brake DOT-3 liquid
or DOT-4
Pusher of the main cylinder, axis of a pusher and washer
Greasing for bearings of naves of wheels of SAE J310a, NLGI No.2
Axis and plugs of a pedal of coupling
  SAE J310a,  greasing  for  the chassis, NLGI-No.1
Surface of contact of a fork of switching off of coupling with a pusher of the working cylinder
CASMOLY L9508

Removal and installation of coupling and its drive

Fig. 3.1. Cцепление and its drive: 1–fork of switching off of coupling; 2–bearing of switching off of coupling; 3–bolt of fastening of a casing of coupling; 4–coupling casing; 5–a conducted disk of coupling; 6–pipeline of a drive of coupling; 7–arm of a pedal of coupling; 8–axis of a pedal of coupling; 9–coupling pedal; 10-main cylinder of a drive of coupling; 11-working cylinder of a drive of coupling; 12-union of pumping of the working cylinder of a drive of coupling


Coupling and its drive are shown on fig. 3.1 .
Air removal from a coupling hydraulic actuator
Pumping of a hydraulic actuator of coupling it is necessary to carry out each time at removal of the connecting pipeline, a hose and/or the main cylinder, and also in a case when the pedal of coupling becomes "soft".

PREVENTION
Use working liquid only the specified brand. Do not mix some liquid of different brands. Use DOT-3 or DOT-4 liquid.


Fig. 3.2. Arrangement of the union of pumping of a hydraulic actuator of coupling


Weaken an union inhaling for pumping on the working cylinder (fig. 3.2) .
Slowly press against the stop a coupling pedal until the liquid effluence will stop.
Holding a pedal in the pressed situation, tighten the pumping union.
Add to normal level in a tank liquid of demanded brand.

Main cylinder of a hydraulic actuator of coupling

Fig. 3.3. Main cylinder of a drive of coupling: 1–case of the main cylinder of a drive of coupling; 2–nut of fastening of the main cylinder of a drive of coupling; 3–piston; 4–lock ring; 5–a pusher with a damper; 6–pusher axis


The main cylinder of a hydraulic actuator of coupling is shown on fig. 3.3 .
Removal
Merge working liquid via the pumping union.

Fig. 3.4. Nut of fastening of the main cylinder of a drive of coupling


Unscrew a nut of fastening of the main cylinder (fig. 3.4) .
Disconnect pipelines and hoses of a hydraulic actuator of coupling.

Fig. 3.5. A clip of fastening of the pipeline to a transmission


Remove a clip of fastening of the pipeline to a transmission (fig. 3.5) .
Check a hose and the pipeline on existence of corrosion, sinks and задиров.
Installation
Attach the pipeline to the working cylinder.

Fig. 3.6. Flexible hose of a hydraulic actuator of coupling


Attach a flexible hose and fix it a clip (fig. 3.6) .
Establish the main cylinder.
Attach a pusher to a coupling pedal.
Pump over a coupling hydraulic actuator.
Dismantling
Remove a lock ring of the piston.
Take out a pusher assembled with the piston, thus watch to damaging the case and the cylinder piston.
Check of a technical condition
Check a cylinder mirror on existence of corrosion, sinks and задиров.
Check a cylinder cuff on wear or distortion existence.
Check the piston on existence of corrosion, sinks go задиров.
Check purity of the pipeline.
Check by means of a nutromer internal diameter of the cylinder and by means of a micrometer external diameter of the piston.
If the gap between the piston and the cylinder exceeds the maximum permissible size (0,15 mm), replace the main cylinder or the piston.
Assembly
Put working DOT-3 or DOT-4 liquid on a mirror of the cylinder and an external surface of the piston.
Insert the piston into the cylinder.
Establish a lock ring of the piston.
Establish a pusher.
Attach a hose to the cylinder case.

Coupling pedal

Fig. 3.7. Pedal of coupling and arm of its fastening: 1–switch of blocking of ignition; 2–pedal arm; 3–bolt of fastening of an arm of a pedal; 4–pedal axis; 5–internal plug of a pedal; 6–returnable spring; 7–external plug of a pedal; 8–internal plug of a pedal; 9–spring washer; 10-nut of an axis of a pedal; 11-pedal emphasis; 12-coupling pedal


The pedal of coupling and arm of its fastening are shown on fig. 3.7 .
Removal

Fig. 3.8. Шплинт axes of a pusher of a pedal of coupling


Remove шплинт and a washer (fig. 3.8) .

Fig. 3.9. Nuts of fastening of a pedal of coupling


Unscrew bolts of fastening of a pedal (fig. 3.9) .
Check of a technical condition
Check the following:
– an axis and the pedal plug on wear existence;
– a coupling pedal on bend and distortion existence;
– a returnable spring on damage or easing existence;
– a pedal platform on damage or wear existence;

Fig. 3.10. Measurement of height of a pedal of coupling over a floor


– pedal height over a floor And (from an external surface of a platform of a pedal to a floor) (fig. 3.10) . It should be 160,7 mm.
If the pedal height over a floor does not correspond to norm, adjust it, as shown below.

PREVENTION
At adjustment of height of a pedal watch that the pusher was not displaced towards the main cylinder.

1. A bolt adjust pedal height then tighten a lock-nut.

PREVENTION
After adjustment tighten a bolt so that it concerned a pedal emphasis then tighten a lock-nut.

Fig. 3.11. Height over a floor and a course of a pedal of coupling


2. Rotation of a pusher adjust its length on new height of a pedal (fig. 3.11) then fix a pusher a nut.

Fig. 3.12. Free wheeling of a pedal of coupling


Upon termination of adjustment be convinced that the free wheeling of a pedal of coupling (measured from a surface of a platform of a pedal) is in limits of 6-13 mm (fig. 3.12) .
If the free wheeling of a pedal of coupling does not correspond to norm, means, air got to a hydraulic actuator or the main cylinder is faulty. Pump over a hydraulic actuator and check the main cylinder or coupling.

Fig. 3.13. The scheme of check of an integrity of an electric chain between switch contacts


Check of the switch of blocking of ignition. Check an integrity of an electric chain between switch contacts (fig. 3.13) .
Installation

Fig. 3.14. Places of drawing of universal greasing


Put universal greasing in the places specified by shooters fig. 3.14 .
Wrap nuts (fig. 3.9) .
Establish шплинт axes of a pedal of coupling.

Casing of coupling and conducted disk

Fig. 3.15. A casing of coupling and a conducted disk: 1–fork of switching off of coupling; 2–bearing of switching off of coupling; 3–bolt of fastening of a casing of coupling; 4–coupling casing; 5–a conducted disk of coupling


The casing of coupling and conducted disk are shown on fig. 3.15 .
Removal
Merge liquid from a hydraulic actuator of coupling and oil from a transmission case.
Remove a transmission (see the subsection "Transmission").
Insert an opravka 09411-25000 into an opening of a nave of a conducted disk not to allow its falling.
Weaken cross-wise an inhaling of bolts of fastening of a casing of coupling to a flywheel.

Fig. 3.16. Weakening of bolts of fastening of a casing of coupling to a flywheel


Bolts unscrew serially, each time on one-two turn to prevent a buckling of a flange of a casing (fig. 3.16) .

PREVENTION
Do not apply solvents to cleaning of a conducted disk and the bearing of switching off of coupling.

Checking of a technical condition
Coupling casing. Check the ends of petals of a diafragmenny spring on existence of wear and a difference of heights.
Check a surface of a press disk on existence of wear, cracks and color change.
Check existence of the weakened rivets and if necessary replace a coupling casing.
Conducted disk. Check frictional overlays for existence of the weakened rivets, traces of a non-uniform prileganiye, damages from a prikhvatyvaniye, oil or greasing sticking. If necessary replace the damaged conducted disk.

Fig. 3.17. Check of thickness of a conducted disk in the free (not loaded) condition


Check thickness of a conducted disk in a free condition (fig. 3.17) .
Check disk springs on existence люфта and damages, if necessary replace a faulty disk.
Clear shlitsa of primary shaft of a transmission and establish a conducted disk.
At the complicated moving of a disk on shlitsa of a shaft or existence of its excessive gap replace a conducted disk and/or primary shaft of a transmission.

PREVENTION
In the bearing of switching off of coupling greasing is put. Do not apply solvents to bearing cleaning.

Bearing of switching off of coupling. Check the bearing of switching off of coupling on existence of jamming, damages or the increased noise. Check points of contact of a diafragmenny spring with a bearing holder on wear existence.
Replace the bearing at strong wear of places of contact to a fork of switching off of coupling.
Fork of switching off of coupling. Replace a fork of switching off of coupling at strong wear in places of contact to the bearing of switching off of coupling.
Installation
Put universal greasing on a fork of switching off of coupling in places of contact to the bearing of switching off of coupling and the working cylinder.

Fig. 3.18. A place of drawing of universal greasing on a fork of switching off of coupling


Put greasing (see fig. 3.18 ).
Put universal greasing in a flute of the bearing of switching off of coupling.
Recommended greasing – CASMOLY L9508.
Put universal CASMOLY L9508 greasing on a fork of switching off of coupling in a place of contact to an axis of the lever of switching off of coupling.
Carefully clear surfaces of a flywheel and a press disk a fine-grained skin and be convinced of lack of traces of oil on them or greasings.
Put a small amount of universal CASMOLY L9508 greasing on a shlitsa of a nave of a conducted disk and primary shaft of a transmission.

PREVENTION
Fig. 3.19. Bolts of fastening of the working cylinder of coupling

At installation of coupling do not put too much greasing in 3.19 places specified fig. as it can lead to pro-slipping and breakthroughs at coupling work.

By means of an opravka 09411-25000 establish a conducted disk on a flywheel the party with factory marking to a press disk.
Establish on a flywheel a casing of coupling and screw six bolts of fastening.
Tighten bolts cross-wise the moment of 15-22 N · m. Bolts tighten serially, each time on one-two turn to prevent a buckling of a flange of a casing of coupling.
Take out an opravka for a centering of a conducted disk.
Establish a transmission (see the subsection "Transmission").
Adjust a free wheeling of a pedal of coupling.

PREVENTION
Put only necessary amount of greasing. Surplus of greasing can cause pro-slipping and breakthroughs at coupling work.

Working cylinder of a drive of coupling
Removal
Disconnect from the working cylinder the connecting pipeline.

Fig. 3.20. Piston removal from the cylinder


Unscrew a bolt of fastening of the working cylinder (fig. 3.20) .
Check of a technical condition
Check the working cylinder on existence of traces of leakage of liquid.
Check a cover of the working cylinder on existence of damages.
Dismantling
Disconnect from the cylinder a connecting hose, remove a valve plate, a spring, a pusher and a cover.
Carefully remove dirt round boring of the working cylinder under the piston.
Remove the piston from the cylinder with a stream of the compressed air directed to the cylinder (fig. 3.20) .

PREVENTION
Previously cover the working cylinder with rags as the piston can take off with a high speed and put a trauma.

Pressure of air increase gradually to prevent emission of brake liquid and its hit in eyes or on skin.
Check of a technical condition
Check a mirror of the working cylinder on absence of corrosion or damages.
By means of a nutromer check internal diameter of the cylinder in three places (in the bottom, average and top parts). If the gap between the piston and the cylinder exceeds maximum permissible, replace the working cylinder.
Maximum permissible gap between the piston and the cylinder of 0,15 mm.
Assembly
Put brake liquid of demanded brand on an internal surface of the working cylinder both an external surface of the piston and a cuff of the piston and establish the piston in the cylinder.
Used liquid: brake DOT-3 or DOT-4 liquid.
Installation
Establish a valve plate, a pusher and a cover.
Put on a pusher axis CASMOLY L9508 greasing.
Establish the working cylinder of a drive of coupling and attach to it the pipeline.

Fig. 3.21. Bolts of fastening of the working cylinder of coupling


Screw bolts of fastening of the working cylinder (fig. 3.21) .

Useful data and councils
The reasons of pro-slipping of coupling or its incomplete switching off by pressing a pedal
Pro-slipping of coupling is shown that at quite serviceable engine the car badly overcomes liftings, slowly dispersed. It can be caused by a zamaslivaniye or strong wear of disks, decrease in elasticity of springs, lack of a free wheeling of a pedal of coupling.
Incomplete switching off of coupling causes difficulty and noise at gear shifting and can lead to premature failure of synchronizers and the accelerated wear of teeths of a transmission. This malfunction arises at pollution, a distortion or deformation of disks, the wrong adjustment of position of levers of switching off, too big free wheeling of a pedal of coupling more often.
It is necessary to mean that noise in a transmission is not always a consequence of incomplete switching off of coupling. Noise can arise at wear or the wrong adjustment of bearings, wear or the wrong gearing of conic gear wheels. Strong knock in the specified places testifies to existence of the serious malfunction demanding an immediate stop of the car and repair of the unit.
The reasons of the complicated gear shifting or their spontaneous switching off
The complicated gear shifting or their spontaneous switching off – result of wear of locks and clamps or a drive of the mechanism of gear shifting. Here without serious repair not to manage.
To warn similar malfunctions it is possible the next ways: periodically carefully to check reliability of fastening of all units and details of a power transmission, to watch oil level in a transmission and in due time to change it.