8G 5 speed hyundai sonata swap.
Ok so i basically got the whole swap done and its not so difficult.
heres the parts list.
99-05 hyundai sonata/01-06 kia optima 2.4 manual
"M/T starter"
flywheel bolts M/T only
Transmission & mount
slave/master cylinder
flywheel/clutch
clutch pedal
floor shifter & cables
rear mount adapter plate (which can be taken off the automatic)
reverse solenoid plug
3g brake pedal
heres the modifications
1)transmission mount.
In this picture i had to to cut the sides off where the bolt slides through. make sure to cut right next to the rubber .reason to cut because they were to long and wouldnt fit inside the mount holder on the galant.
http://i71.photobucket.com/albums/i1...p/Photo555.jpg
http://i71.photobucket.com/albums/i1...p/Photo556.jpg
2) remove the transmission mount adapter plate. this will correct the alignment of the transmission sitting in the engine bay.
http://i71.photobucket.com/albums/i1...p/Photo602.jpg
http://i71.photobucket.com/albums/i1...p/Photo603.jpg
3) The holes on the transmission wont line up with the mount. so i had to cut slots on the 2 top holes of the mount.
http://i71.photobucket.com/albums/i1...p/Photo609.jpg
4) Take the rear mount adapter plate and arm off of the automatic tranny.And install it on the sonata.
5)The rear holes on the floor shifter wont line up. easy fix is to drill 2 holes . install a bolt up top and a nut at the bottom.
01-04 SANTA FE m/t 2.4 options.
since the santa fe shares alot of the same parts with research i was able to find these.
1)single plain flywheel :
The good: very cheap compared to dual plain.
lighter.
The bad: alittle harsher when engaging compared to a dual plain.
I bought mine off of ebay for 110$.http://stores.ebay.com/Car-Parts-Dis...&submit=Search
2)starter: santa fe and sonata shares the same starter.( make sure its a manual starter!)
3g eclipse/galant options
1) you can use a eclipse brake pedal.
2)I recommend changing the axle seal to a eclipse or galant
The things you should know
1)The part of the cables that gets bolted to the fire wall isn't as big as the galants so it just goes through kind of easy. easy fix is to take the plate of the galant cables and put it on the sonatas.
*2)getting the top bolt in to the clutch pedal is pretty hard. I basically got the 2 nuts(for the master cylinder and clutch pedal stud) on the pedal like half way so i can turn the pedal for that top bolt could line up with the hole. take your time you'll need that top bolt for clearance since the pedal will sit too close to the floor.
*3)make sure you adjust your clutch pedal and rod out as much as possible. the pedal should come out a little further then your brake pedal. I used the eclipse fork to push the pedal out further.
http://i71.photobucket.com/albums/i1...p/Photo643.jpg I also cut out the clutch saftey switch nut to give it more clearance which isnt required.
*4)you have to remove your pilot bearing. I used the tissue method to get it out. the first time ever i simply yanked it out but this time it was tough to get out.http://i71.photobucket.com/albums/i1...p/Photo629.jpg
*5) when you install your sonata transmission turn the throw out bearing rod counter clock wise . you'll know when the throw out bearing is properly seated cause you wont be able to turn clock wise easy. only do this when the transmission is bolted to the engine. In this picture its the rod that the slave arm is on.http://i71.photobucket.com/albums/i1...p/Photo645.jpg
6) make sure if your using a sonata mount use the rubber spacer. You need to squeeze them in there bending the mount arm might help out. This will stop the vibration noise. The rubber spacer that came off the auto will fit well.
http://i71.photobucket.com/albums/i1...p/Photo644.jpg
I believe thats all basically follow the regular 5 speed swap https://www.thegalantcenter.org/showthread.php?t=16557 with the things i mentioned here and your good to go.
I know its not a step by step its basically a parts list in specific detail.
here are the speed to gear raitio with the 4g64 on 225-40-18
1 2 3 4 5
0 0.0 0.0 0.0 0.0 0.0
500- 2.7 4.8 7.2 9.8 12.0
1000 5.4 9.5 14.3 19.7 23.9
1500 8.1 14.3 21.5 29.5 35.9
2000 10.7 19.1 28.6 39.3 47.9
2500 13.4 23.8 35.8 49.2 59.8
3000 16.1 28.6 42.9 59.0 71.8
3500 18.8 33.4 50.1 68.9 83.8
4000 21.5 38.1 57.3 78.7 95.8
4500 24.2 42.9 64.4 88.5 107.7
5000 26.8 47.6 71.6 98.4 119.7
5500 29.5 52.4 78.7 108.2 131.7
6k- 32.2 57.2 85.9 118.0 143.6 mph
file:///C:/Documents%20and%20Settings/exhaust/My%20Documents/Downloads/Speed%20RPM%20Calculator.htm
This tranny ratio is good for s 6.5-7k redline n/a set up wich is good for me.