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Hyundai Santa Fe - 2012 Santa Fe 2.2 Diesel - auto gearbox change not - Simonemery555

Hi Guys,
I'm a newby on here, but post regularly on other forums

I really need help on this. I have a Hyundai Santa Fe 2012 2.2 Diesel with a 6 speed auto gearbox, which i have owned for 2 years. The gearbox randomly clonked since i bought the car (35k miles), but last month started slipping in 3/4th gear (80k miles). I had to drive a 350 mile return trip, and it eventually stuck in 4th gear permanently. The next day 1st gear and 2nd gear started to slip bad and it finally gave up. I checked the fluid and it was horrible, so it had deffo crapped itsself.

ok so onto the trouble...

I bought a like for like gearbox with torque converter from a breakers, who assured would fit, but it came from a low mileage 2016 2.2d model that had been side/rear-ended. it looks identical and fits. For clarity, mine is the version 2 Santa Fe, and the new box came off a version 3.

I have removed my old gearbox and TC. Then i fitted the new TC to the new gearbox - span it round and round till it went back a couple of times to what i believe is the correct and final depth possible, fitted it to my engine, bolted the TC to the flex/drive plate, and it seems to come together nicely. When trying to start the car, nothing happened, so it seemed the gear position sensor was off - i played and played to no avail, and ended up using my old sensor and hey presto the starter motor tried to work.

....But it couldn't crank the engine, and neither could I by hand.. until i backed the box of the engine by 1-1.5mm. So it appears the TC is just slightly getting pushed against the bell housing and getting jammed. I spoke briefly to a mechanic who suggested it was probably a slight change in the flex/drive plate that would alter the distance, so i purchased for £72 the new plate from hyundai, but when measuring them side by side they are identical depths, (the new one is lightweight with vents in).

What am i doing wrong? when comparing the TC, they are visually different on the face where they bolt to the plate. I don't want to try my TC as its full of dirty fluid - i'm not sure if its possible to clean it out at home..? The TC just seems like its too just big to fit between my engine and gearbox.

When speaking to Hyundai parts to order the flex plate, he said they charge for the gearbox on my model £3k to buy, where as the one from the donor cars number plate costs £6k to buy, so they are very different models. I'm thinking (hoping now) that the internals have been improved due to all the problems they cause, but the dimensions and function should be the same.

At this point i have gone past the return date of the new gearbox as it was delivered whilst i was away at a conference, I've invested a ton of wasted time and money for what seems like a hair sized difference in the TC.

I welcome any thoughts as this is driving me mental, i'm lacking transport, and has been a eyesore on the drive to my neighbours for the last 2 weeks .

Help!

Simon

Hyundai Santa Fe - 2012 Santa Fe 2.2 Diesel - auto gearbox change not - elekie&a/c doctor

"it looks identical and fits" .Fatal error when dealing with s/hand parts on modern cars.Unless the part is 100% identical with the same part numbers,then you are going to run into trouble,as you have found out. Makers can, and do, make various changes to components that may seem minor ,but make a big difference. Why can't you get the old box re-built?

Hyundai Santa Fe - 2012 Santa Fe 2.2 Diesel - auto gearbox change not - Big John

"it looks identical and fits" .Fatal error when dealing with s/hand parts on modern cars.Unless the part is 100% identical with the same part numbers,then you are going to run into trouble,as you have found out. Makers can, and do, make various changes to components that may seem minor ,but make a big difference. Why can't you get the old box re-built?

This has been the case for many decades - I once had to fit a Ford MKI Cortina engine to a MKII Cortina (port side not crossflow) and had to fit spacer washers between the engine and gearbox bellhousing to allow it to turn. Theoretically the same but it wasn't!

Edited by Big John on 15/11/2018 at 23:28

Hyundai Santa Fe - 2012 Santa Fe 2.2 Diesel - auto gearbox change not - skidpan

This has been the case for many decades - I once had to fit a Ford MKI Cortina engine to a MKII Cortina (port side not crossflow) and had to fit spacer washers between the engine and gearbox bellhousing to allow it to turn. Theoretically the same but it wasn't!

All 4 cylinder (excluding the V4's) Ford engines from the pre x-flow to the Mondeo/Mk 1 Focus Zetec used the exact same mounting bolt pattern. The Yamaha based Sigma engine and the Mazda based Duratec were different.

All Ford in line gearboxes from the 4 speed box used in the reverse window Anglia to the MT75 used in the last of the Sierras either had an integral bellhousing to fit this pattern or had a bellhousing to suit the 4 cylinder bolt pattern.

All these engine/gearbox combinations had one thing in common, a metal spacer plate/dust shield (call it what you like) that fitted between the engine and bellhousing.

Since the early 80's I have fitted many combinations of engines/gearboxes and never had an issue but I have always used the spacer plate. I have come across people in the Caterham community who haven't and some have been lucky and some not. When the crank is machined not all have the same length hole for the gearbox input shaft and equally not all input shafts are the exact same length. Get a long hole and a short shaft and it will be fine without the plate but get a short hole and a long shaft and it will 100% ground before the engine and bellhousing are fully tight without the plate.

2 examples. A friend of mine bought a Caterham fitted with a MT75 box onto a x-flow (not a factory option with Caterhams but it was with Westfields). After he had owned it for a while the engine went bang in a big way and he enlisted my help. When we stripped it the center main bearing had snapped out of the block and the crank was in 2 pieces. The car builder had not fitted a spacer plate and the result was a totally wrecked engine. New engine acquired, gearbox rebuilt (just in case it too had been stressed) and assembled with spacer plate and all OK. Another friend was fitting the engine and box together for the first time with no spacer plate and he did not gET as far as tightening all the bolts fully. One of the mounting lugs on the engine snapped off wrecking the block. Engine rebuilt and assembled with spacer plate and no issues.

Over the years many spacer plates were omitted after work by less experienced mechanics. They tended to fall out when the engine/box were split to fit a new clutch and were left where they fell. Most owners were lucky I guess.

How thick was the plate, about 3mm or the thickness of a couple of washers.

Hyundai Santa Fe - 2012 Santa Fe 2.2 Diesel - auto gearbox change not - Simonemery555

yes the plate is a couple/3mm.

i cant see the box's being that different to be honest, the net is covered with horror stories of failed auto boxes for my generation of santa fe, so i'm thinking the new box will be improved internals only.

after measuring both old and new with a digital ruler, they are the same depth from the bell housing to the bolt hole. either im cack at putting the TC in the gearboxes and both have not gone as far back as they should now, or i must of pulled it off to far when reattaching the flexplate. Im attaching my olf flexplate back and returning the £72 metal disk to hyundai. how they can charge that much for it i will never know.

Hyundai Santa Fe - 2012 Santa Fe 2.2 Diesel - auto gearbox change not - RT

yes the plate is a couple/3mm.

i cant see the box's being that different to be honest, the net is covered with horror stories of failed auto boxes for my generation of santa fe, so i'm thinking the new box will be improved internals only.

after measuring both old and new with a digital ruler, they are the same depth from the bell housing to the bolt hole. either im cack at putting the TC in the gearboxes and both have not gone as far back as they should now, or i must of pulled it off to far when reattaching the flexplate. Im attaching my olf flexplate back and returning the £72 metal disk to hyundai. how they can charge that much for it i will never know.

Careful now - the net is full stories of failed Santa Fe gearboxes from the first year of US production sold only in North America - the specific fault affecting those gearboxes wasn't present in the Korea-built Santa Fe's sold in Europe.

As a keen member of both the UK and International forums covering Santa Fe, the issue was a non-event in Europe. The 6-speed automatic is fairly robust and generally trouble-free - particularly if the ATF is changed every 40-80,000 miles dependent on whether towing or not.

As this transmission wasn't right at 35,000 with "clonking" and nothing done 'till 80,000 the result was probly inevitable.

Edited by RT on 16/11/2018 at 15:44

Hyundai Santa Fe - 2012 Santa Fe 2.2 Diesel - auto gearbox change not - Simonemery555

"it looks identical and fits" .Fatal error when dealing with s/hand parts on modern cars.Unless the part is 100% identical with the same part numbers,then you are going to run into trouble,as you have found out. Makers can, and do, make various changes to components that may seem minor ,but make a big difference. Why can't you get the old box re-built?

i could of, but the minimum ii was quoted was £3k, which made the £1.2k gearbox a 'steal', and frankly just before christmas i don't have the funds :(

I've actually measured the distances between the bolt holes and the bell housing lip on both. they are identical. so i thinking I might of pulled it to far when bolting the TC to the flex plate. I'm praying i have not done any damage to the pump, but i think its not likely as its just over a millimetre of squashing.

New problem though - im finding it extremely difficult to reattach the flexplate to the motor with the adaptor plate on top. its like they are just slightly misaligned to be some sort of locking mechanism, i've only managed to lightly put in the first 4 out of 8 bolts in.

Hyundai Santa Fe - 2012 Santa Fe 2.2 Diesel - auto gearbox change not - skidpan

As this transmission wasn't right at 35,000 with "clonking" and nothing done 'till 80,000 the result was probly inevitable

Only just realised. You bought a 2012 Santa Fe in 2016 with a "clonking" gearbox. It would still have had some of Hyundai's 5 year unlimited mileage warranty left so why on earth did you not take it for the garage to fix free of charge.

Bit late now, horse and stable door etc.

Hyundai Santa Fe - 2012 Santa Fe 2.2 Diesel - auto gearbox change not - RT

As this transmission wasn't right at 35,000 with "clonking" and nothing done 'till 80,000 the result was probly inevitable

Only just realised. You bought a 2012 Santa Fe in 2016 with a "clonking" gearbox. It would still have had some of Hyundai's 5 year unlimited mileage warranty left so why on earth did you not take it for the garage to fix free of charge.

Bit late now, horse and stable door etc.

Excellent point well made.

Hyundai Santa Fe - 2012 Santa Fe 2.2 Diesel - auto gearbox change not - Simonemery555

i never felt it myself, but the missus reported it several times to me. i wasnt sure what it was at the time.. lesson learned.

also, IIRC the warranty ran out ~3 months after buying it.

 

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