Replacing a gearbox synchronizer on a Hyundai Terracan J3 with a Delphi common rail engine involves several steps. click here for more details on the download manual…..
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Here’s a reverse order explanation of the process:
### 1. **Reassemble the Gearbox**
– **Install the Gearbox Cover**: Secure the gearbox cover back onto the gearbox casing using the appropriate bolts.
– **Reconnect Gear Linkage**: Attach the gear linkage to the gearbox, ensuring it is properly aligned.
– **Install the drive Shafts**: Reinstall the drive shafts, ensuring they are secured and properly fitted into the differential.
### 2. **Refill Transmission Fluid**
– **Add Gear Oil**: Refill the gearbox with the correct type and amount of gear oil as specified in the vehicle’s service manual.
### 3. **Install the Gearbox**
– **Position the Gearbox**: Carefully lift the gearbox into place on the engine, ensuring alignment with the engine mounts and transmission bell housing.
– **Secure the Gearbox**: Use the bolts to secure the gearbox to the engine block, tightening them to the manufacturer’s specifications.
### 4. **Remove the Old Synchronizer**
– **Extract the Old Synchronizer**: Once the gearbox is opened, carefully remove the old synchronizer rings and the associated components from the gearbox.
### 5. **Disassemble the Gearbox**
– **Remove the Gearbox from the Vehicle**: Disconnect any necessary components (e.g., exhaust, crossmember) and lower the gearbox from the vehicle.
– **Remove the Input and output Shafts**: Take out the input and output shafts of the gearbox to access the synchronizer assembly.
### 6. **Gain Access to the Synchronizer Assembly**
– **Remove the Gear Selector Forks**: Take out the gear selector forks to gain access to the synchronizer.
– **Detach the Shift Mechanism**: remove any shift mechanisms or rods that may obstruct access to the synchronizer.
### 7. **Prepare for Replacement**
– **Gather Tools and Parts**: Ensure you have all necessary tools (sockets, wrenches, etc.) and the new synchronizer rings or assembly ready for installation.
– **Clean Components**: Clean all components and inspect them for wear or damage before reassembly.
### 8. **Safety Precautions**
– **Disconnect the Battery**: Always disconnect the vehicle’s battery before starting work on the electrical or mechanical systems.
– **Lift the vehicle Safely**: Use jack s
tands or a lift to safely elevate the vehicle for easier access.
### Important Notes:
– Always consult the vehicle’s service manual for specific torque specifications and procedures.
– Be cautious of the gearbox’s weight and handle it carefully to avoid injury or damage.
– Ensure that all seals and gaskets are replaced as needed to prevent leaks.
This reverse order explanation helps in visualizing the entire process from completion to the start, aiding in Understanding the steps involved in replacing a gearbox synchronizer.
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