94 Excel Clutch Replacement Instructions

On your way to work in your paid-off 1994 Hyundai Excel, you press gently down on the accelerator and your tachometer revs up high but the car doesn't respond like it used to. It's taking far more rpms to get your car moving than it should. You are experiencing a problem with your clutch and you need to replace it before more damage is done. If you are driving an automatic transmission, this means your whole transmission is failing. The Hyundai Excel is a carbon copy of the frame, mounts and style of the Mitsubishi Mirage so many of the parts and repair instructions are interchangeable.

Instructions

1

Ensure your clutch kit has the following parts: Clutch wheel, grease, alignment tool, and throw out bearing.

2

Park the Excel on a level surface, preferably a concrete driveway, and jack up the front end of the vehicle. Place a jack stand under each side of the undercarriage of the car to hold it safely in place.

3

Remove the lug nuts from the front tires with a tire iron or pneumatic drill and place the lug nuts and tires to the side.

4

Use a socket wrench to remove the bolts holding the wheel assembly on, disconnect the brake lines by sliding them off the brake assembly and plug them with a small rubber stoppers to prevent leaks. Set these aside.

5

Drain the transmission fluid by removing the drain plug located behind the passenger side wheel. Catch the fluid in a pan to prevent discoloring driveway stains and leakage into sewers.

6

Remove the drive shafts by inserting a pry tool into the inside of the CV shaft and pulling it off. Remove the other CV shaft as well and set these aside.

7

Remove the bolts on the clutch slave cylinder with a socket wrench and move it out of your way.

8

Place a third jack stand under the transmission casing and jack it up so it can support the bottom of the transmission when the bolts are removed to replace the clutch.

9

Remove the starter bolts and all the other bolts that hold the transmission to the engine block with a socket wrench or a breaker bar if you can't reach the bolts.

10

Take off the transmission mount with a socket on a breaker bar. This bolt will be rather tight so you will need the breaker bar.

11

Use the pry bar to separate the clutch wheel from the transmission. Unbolt the small bolts with a socket or, if you don't have one small enough, try using an adjustable wrench. These six small bolts are holding the clutch wheel to the transmission. Once these six bolts are removed, you can remove the clutch wheel. Pry the clutch wheel away from the transmission and pull the clutch pieces out of the wheel. Remove the throw out bearing from the spline and throw it out.

12

Apply some of the grease from the kit to the spline of the transmission so the clutch wheel can be reinstalled easily.

13

Replace the clutch pieces with the new clutch and bolt the wheel back into place.

14

Place the new throw out bearing over the shaft or spline going into the transmission.

15

Stick the alignment tool from the kit into the clutch so it fits tightly. Press the tool into the center of the clutch and it will force the wheel to sit on the clutch in perfect alignment.

16

Tighten all the bolts on the clutch. Get under the vehicle and lift the clutch into the transmission casing. If needed, have an assistant watch from above as you attempt to slide it back on. Once it is seated properly, tighten the bolts removed earlier, replace the transmission mount bolt and reassemble all the pieces in the reverse order in which you removed them.

17

Pump new transmission fluid into the hole you took it out of and replace the drain plug. Your Excel is now ready for a test drive.