Sonata V6-3.0L (1991)
7.
If the servo piston cannot be moved out of the bore, remove the plug from the kickdown brake pressure port and apply air (no more than 25 psi) to
the port to move the servo assembly outward for easy removal.
CAUTION
Hold a rag over the bore to catch the servo piston.
8.
Separate the kickdown servo sleeve from the servo piston. Remove the 0-ring on the servo sleeve and replace it with a new one. Remove the
D-rings from the servo piston and replace them with new ones. Always lubricate the rubber 0-rings and D-rings with ATF before assembly.
NOTE
Check the kickdown servo bore for scratches and nicks. Polish the bore with emery cloth, if necessary.
9.
For vehicles with an air exhaust plug, check the air exhaust plug with a steel wire and ensure that the steel retainer is in position as show in TSB
number 92-40-007. If the steel retainer has come out of position and entered the kickdown servo bore, scoring of the bore may have occurred.
Light scoring may be polished out. Deep scoring will require ATM case replacement.
10.
Carefully reinstall the kickdown servo assembly into its bore and install the snap ring.
11.
Using the kickdown servo wrench, 09454-33101B, turn the kickdown servo rod clockwise and torque to 10 Nm 7.2 lb.ft.
CAUTION
Confirm that the locknut is loose on the servo rod and does not interfere with the torque adjustment.
12.
Loosen the servo rod two turns.
13.
As a final step, torque the servo rod to 5 Nm 3.6 lb.ft. then loosen the servo rod 2 to 2-1/4 turns.