Overhaul Procedures: Reassembly

CAUTION:

Keep the workbench and parts always clean and dirt free.
Do not use cotton gloves. Use paper towel and nylon rag. Do not use nappy fabric.
Do not use grease at any place otherwise specified. Use white vaseline or blue mineral oil if necessary.
Insert each snap ring firmly into the seat. Do not use deformed rings.
Do not allow dirt to remain on the surface to apply liquid gasket during reassembly.
Oil pump gasket, valve body mounting bolts (6X25) and oil seals shall not be used again, and use the new ones in assembly.
New clutch and brake discs shall be dipped in ATF for 2 hours or more before use.
In reassembly, replace ATF and cleanse its filter thoroughly. Replace the damaged filter element with a new one.
Apply required minimum quantity of white vaseline, blue mineral oil, or ATF on each of the bearing part, the thrust face moving part, the oil pump moving part, the seal ring, and the O-ring.
Do not replace the ATF in the fluid cooler.
Be careful not to allow dirt to come through the transaxle openings before transaxle mounting onto the vehicle. (including electronic part connector).

Using SST (09493-2F300), install the differential oil seal on the transaxle case(B).

Fig 1: Installing Differential Oil Seal On Transaxle Case Using SST (09493-2F300)
Courtesy of KIA MOTORS AMERICA, INC.
After applying grease, install the transfer drive gear (A) (8 screws).
TORQUE :

8~12Nm(80~120Kgf.cm, 6~8lb-ft)

Fig 2: Locating Transfer Drive Gear And Screws
Courtesy of KIA MOTORS AMERICA, INC.
Install the Low & reverse brake piston(A).
CAUTION: When installing, make sure that the finger of Low and reverse brake piston is seated correctly in groove on the transaxle case.

Fig 3: Locating Low & Reverse Brake Piston
Courtesy of KIA MOTORS AMERICA, INC.
Install the return spring(A).

Fig 4: Locating Return Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the Low & reverse brake spring retainer(A).

Fig 5: Locating Low & Reverse Brake Spring Retainer
Courtesy of KIA MOTORS AMERICA, INC.
Using the special tool(09493-2F400), install the snap ring(A).

Fig 6: Installing Snap Ring Using Special Tool(09493-2F400)
Courtesy of KIA MOTORS AMERICA, INC.
Install the wave spring(A).

Fig 7: Locating Wave Spring
Courtesy of KIA MOTORS AMERICA, INC.
In order to measure the Low & reverse brake end play, install the Low & reverse brake plates(5), discs(6), special service tool, reaction plate(1) and snap ring with the special service tool(0.079in(2mm)) instead of the selected plate.

Fig 8: Identifying Reaction Plate And Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.

Applying 49N(5Kgf, 11lbf) weight and 245.17kPa(2.5 Bar, 35.56psi) air pressure on the plates and discs, measure the end play. At that time, measure the actual gap when releasing the clutch.

Standard value : 0.045~0.057in(1.15 ~1.45mm)

Fig 9: Measuring End Play When Applying 49N(5Kgf, 11lbf) Weight And 245.17kPa(2.5 Bar, 35.56psi) Air Pressure On Plates And Discs

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Choose the proper plate as followed.
For keeping accuracy, measure at least 3 places and calculate the average value.
Pressure plate = [A(travel) + special service tool(0.079in(2.0mm)) - Standard value(0.070in(1.8mm))]

Pressure plate

PRESSURE PLATE REFERENCE CHART

Identification symbol	Thickness [in(mm)]
45635-23170	0.067(1.7)
45635-23190	0.075(1.9)
45635-23210	0.083(2.1)
45635-23230	0.091(2.3)
45635-23250	0.098(2.5)
45635-23270	0.106(2.7)
45635-23290	0.114(2.9)

Select the proper plate. After disassembling the snap ring, reassemble the selected plate(C) instead of the special service tool(0.079in(2.0mm)), snap ring, low & reverse brake discs(A) and plates(B) and then install the snap ring.

Fig 10: Identifying Low & Reverse Brake Discs And Plates
Courtesy of KIA MOTORS AMERICA, INC.

Fig 11: Locating Low & Reverse Brake Discs And Plates
Courtesy of KIA MOTORS AMERICA, INC.
In order to measure the 2ND brake end play, install the special service tool(0.079in(2.0mm)) instead of the selected plate.
1. Install the 2ND brake plate(3), disc(4) and the special service tool(0.079in(2.0mm).
2. Install the 2ND brake return spring(A).
  CAUTION: Make sure that the flat face of the return spring should be located to the downward.
  
  Fig 12: Locating 2nd Brake Return Spring
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the 2ND brake piston(A).
  
  Fig 13: Locating 2nd Brake Piston
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the piston fixing snap ring(A).
  
  Fig 14: Locating Piston Fixing Snap Ring
  Courtesy of KIA MOTORS AMERICA, INC.

Applying 49N(5Kgf, 11lbf) weight and 245.17kPa(2.5 Bar, 35.56psi) air pressure on the plates and discs, measure the end play. At that time, measure the actual gap when releasing the clutch.

Standard value : 0.03~0.045in(0.85 ~ 1.15mm)

Fig 15: Measuring End Play When Applying 49N(5Kgf, 11lbf) Weight And 245.17kPa(2.5 Bar, 35.56psi) Air Pressure On Plates And Discs

Courtesy of KIA MOTORS AMERICA, INC.

Pressure plate

PRESSURE PLATE REFERENCE CHART

Identification symbol	Thickness [in(mm)]
45668-23200	0.079(2.0)
45668-23220	0.087(2.2)
45668-23240	0.094(2.4)
45668-23260	0.106(2.6)
45635-23280	0.110(2.8)

After selecting the proper plate, disassemble the snap ring, piston, return spring, disc and plate.
Install the one way clutch inner race(A).

Fig 16: Locating One Way Clutch Inner Race
Courtesy of KIA MOTORS AMERICA, INC.
Install the inner race fixing snap(A).

Fig 17: Installing Inner Race Fixing Snap
Courtesy of KIA MOTORS AMERICA, INC.
Install the Low & reverse planetary gear set(A).

Fig 18: Locating Low & Reverse Planetary Gear Set
Courtesy of KIA MOTORS AMERICA, INC.
Install the snap ring(E), 2ND brake, pressure plate(A), return spring, plates(C-3EA), discs(B-4EA), reaction plate (D), return spring and 2ND brake piston.

Fig 19: Identifying Snap Ring, 2nd Brake, Pressure Plate, Return Spring, Plates(C-3EA), Discs(B-4EA), Reaction Plate, Return Spring And 2nd Brake Piston
Courtesy of KIA MOTORS AMERICA, INC.

Fig 20: Locating Snap Ring, 2nd Brake, Pressure Plate, Return Spring, Plates(C-3EA), Discs(B-4EA), Reaction Plate, Return Spring And 2nd Brake Piston
Courtesy of KIA MOTORS AMERICA, INC.
Install the snap ring(A).

Fig 21: Locating Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Install the reverse sun gear(A).

Fig 22: Locating Reverse Sun Gear
Courtesy of KIA MOTORS AMERICA, INC.
After applying the grease, install the thrust bearing(45798-39060).
CAUTION: Be careful not to reverse the direction of the thrust bearing.

Fig 23: Locating Thrust Bearing (45798-39060)
Courtesy of KIA MOTORS AMERICA, INC.
Install the overdrive hub(A).

Fig 24: Locating Overdrive Hub
Courtesy of KIA MOTORS AMERICA, INC.
After applying the grease, install the thrust bearing(45798-39060).
CAUTION: Be careful not to reverse the direction of the thrust bearing.

Fig 25: Locating Thrust Bearing (45798-39060)
Courtesy of KIA MOTORS AMERICA, INC.
Install the reverse & overdrive clutch(A).

Fig 26: Locating Reverse & Overdrive Clutch
Courtesy of KIA MOTORS AMERICA, INC.
After applying the grease, install the thrust bearing(45851-23000).
CAUTION: Be careful not to reverse the direction of the thrust bearing.

Fig 27: Locating Thrust Bearing (45851-23000)
Courtesy of KIA MOTORS AMERICA, INC.
In order to select the thrust race, install the used thrust bearing. Applying 30N(3Kgf, lb) (A) weight, measure the distance between the rear cover contacting surface of transaxle case and the thrust bearing.
NOTE: Put the flat board or something on the transaxle case to keep accuracy when measuring.
For keeping accuracy, measure at least 3 places and calculate the average value.

Fig 28: Measuring Distance Between Rear Cover Contacting Surface Of Transaxle Case And Thrust Bearing Applying 30N(3Kgf, lb) Weight
Courtesy of KIA MOTORS AMERICA, INC.
Measure the distance between the contacting surface of the rear cover and the seating surface of thrust race.

Fig 29: Measuring Distance Between Contacting Surface Of Rear Cover And Seating Surface Of Thrust Race
Courtesy of KIA MOTORS AMERICA, INC.

Choose the proper plate as followed.

Thrust race(in(mm)) = [(A-B)] - end play(0.0098~0.0177in(0.25~0.45mm))].

Thrust race

THRUST RACE REFERENCE CHART

Identification symbol	Thickness [in(mm)]
45853-23013	0.051(1.3)
45853-23014	0.055(1.4)
45853-230015	0.059(1.5)
45853-23016	0.063(1.6)
45853-23017	0.067(1.7)
45853-23018	0.071(1.8)
45853-23019	0.075(1.9)
45853-23020	0.079(2.0)
45853-23021	0.083(2.1)

Install the four seal rings on the rear cover.

Fig 30: Identifying Seal Rings Of Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the thrust race(A) on the rear cover.

Fig 31: Locating Thrust Race On Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the five O-rings on the transmission case.

Fig 32: Identifying O-Rings On Transmission Case
Courtesy of KIA MOTORS AMERICA, INC.
Apply liquid gasket with 0.063in(1.6mm) thickness on the rear cover surface without a pause.
Liquid gasket : Threebond 1281B

Fig 33: Applying Liquid Gasket With 0.063in(1.6mm) Thickness On Rear Cover Surface
Courtesy of KIA MOTORS AMERICA, INC.
Install the rear cover(A) (Bolts:9ea).
TORQUE :

20~27Nm(200~270kgf.cm, 14~19lb-ft)

Fig 34: Locating Rear Cover And Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Insert the four gaskets into feed tube(A) and then install it to the transaxle case.
TORQUE :

28~34Nm(280~340kgf.cm, 19~24lb-ft)

Fig 35: Locating Gaskets And Feed Tube
Courtesy of KIA MOTORS AMERICA, INC.
Install the manual control shaft(A, including the two O-ring), the detent lever(B) and the parking rod(C).

Fig 36: Locating Manual Control Shaft, Detent Lever And Parking Rod
Courtesy of KIA MOTORS AMERICA, INC.
Install the reamer bolt on detent lever.
TORQUE :

8~10Nm(80~100kgf.cm, 6~7lb-ft)
Install the manual control shaft fixing groove bolt.
TORQUE :

8~10Nm(80~100kgf.cm, 6~7lb-ft)

Fig 37: Identifying Manual Control Shaft Fixing Groove Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the detent spring(A).
TORQUE :

8~10Nm(80~100kgf.cm, 6~7lb-ft)

Fig 38: Locating Detent Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the plate(A) and then tighten the reamer bolt.
TORQUE :

8~10Nm(80~100kgf.cm, 6~7lb-ft)

Fig 39: Locating Plate And Reamer Bolt
Courtesy of KIA MOTORS AMERICA, INC.
When installing the driven gear, measure the length(A) between both sides of the driven gear with outer races. Measure the length(A) between both sides of the differential gear with outer races. Calculate the sum of the case length and the housing length.
Specified clearance of driven gear: A-C=-0.0003~0.0035in(-0.01~0.09mm)

Specified clearance of differential gear: A-C=-0.0017~0.0041in(-0.045~0.105mm)

If the calculated value is not within the specified clearance, install the suitable spacer.
Install the driven gear and the outer race.
Install the driven gear(A), the shaft(B) and the sprag spring(C).

Fig 40: Locating Driven Gear, Shaft And Sprag Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the inhibitor switch(A) and the manual control lever(B).
TORQUE(shaft nut) :

17~21Nm(170~210kgf.cm, 13~15lb-ft)

TORQUE(2bolts) :

10~12Nm(100~120kgf.cm, 7~8lb-ft)

Fig 41: Locating Inhibitor Switch And Manual Control Lever
Courtesy of KIA MOTORS AMERICA, INC.
Install the parking rod guide(A) and oil plate(B) (Bolt:2EA).
TORQUE:

8~10Nm(80~100kgf.cm, 6~7lb-ft)

Fig 42: Locating Parking Rod Guide, Oil Plate And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil guide plate(B).
TORQUE:

8~10Nm(80~100kgf.cm, 6~7lb-ft)

Fig 43: Locating Oil Guide Plate
Courtesy of KIA MOTORS AMERICA, INC.
Install the underdrive clutch hub(A).

Fig 44: Locating Underdrive Clutch Hub
Courtesy of KIA MOTORS AMERICA, INC.
Install the thrust bearing(A).

Fig 45: Locating Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Be careful not to reverse the direction of the thrust bearing.
Install the underdrive clutch(A).
NOTE: Check that the underdrive clutch is seated correctly.

Fig 46: Locating Underdrive Clutch
Courtesy of KIA MOTORS AMERICA, INC.
Install the used thrust washer(A).

Fig 47: Locating Thrust Washer
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump gasket(A).

Fig 48: Locating Oil Pump Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Using the guide pin(09493-2F600), install the oil pump(A) (Bolt:7 EA).

Fig 49: Locating Oil Pump, Guide Pin (09493-2F600) And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Measure the end play of input shaft and install the spacer if necessary.
Standard value : 0.024~0.043in(0.6 ~ 1.1mm)

Fig 50: Measuring End Play Of Input Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Install the two new O-rings.

Fig 51: Locating O-Rings
Courtesy of KIA MOTORS AMERICA, INC.
Install the differential outer race(A).

Fig 52: Locating Differential Outer Race
Courtesy of KIA MOTORS AMERICA, INC.
Install the differential gear assembly(A).

Fig 53: Locating Differential Gear Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Using special service tool(09493-2F300), install the oil seal on the torque converter housing.

Fig 54: Installing Oil Seal On Torque Converter Housing Using Special Service Tool (09493-2F300)
Courtesy of KIA MOTORS AMERICA, INC.
Install the two dowels pin on the torque converter housing.

Fig 55: Locating Dowels Pin On Torque Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil separate(A) (Bolt:3EA).
TORQUE:

8~10Nm(80~100kgf.cm, 6~7lb-ft)

Fig 56: Locating Oil Separate And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the spacer(A) on the differential and the transfer driven gear of the torque converter housing.

Fig 57: Locating Spacer Of Differential
Courtesy of KIA MOTORS AMERICA, INC.
Install the driven gear race(A) and the driven gear outer race(B) of the torque converter housing.

Fig 58: Locating Driven Gear Race And Driven Gear Outer Race Of Torque Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Apply liquid gasket with 0.063in(1.6mm) thickness on the torque converter housing without a pause.
Liquid gasket : Threebond 1281B

Fig 59: Applying Liquid Gasket With 0.063in(1.6mm) Thickness On Torque Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Install the torque converter housing and tighten the bolt(Bolt: 17EA).
TORQUE :

43~55Nm(430~550kgf.cm, 32~41lb-ft)

Fig 60: Identifying Torque Converter Housing And Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the input shaft speed sensor(A) (Bolt:1EA).
TORQUE :

10~12Nm(100~120kgf.cm, 7~8lb-ft)

Fig 61: Locating Input Shaft Speed Sensor And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the output shaft speed sensor(A) (Bolt:1EA).
TORQUE :

10~12Nm(100~120kgf.cm, 7~8lb-ft)

Fig 62: Locating Output Shaft Speed Sensor And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the plug(A).

Fig 63: Locating Plug
Courtesy of KIA MOTORS AMERICA, INC.
Install the shift cable bracket(A) (Bolt:2EA).
TORQUE :

19~23Nm(190~230kgf.cm, 14~17lb-ft)

Fig 64: Locating Shift Cable Bracket And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil level gauge(A) and bracket(Bolt:2EA).
TORQUE :

19~23Nm(190~230kgf.cm, 14~17lb-ft)

Fig 65: Locating Oil Level Gauge, Bracket And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the control valve connector(A).

Fig 66: Locating Control Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.

Insert each accumulator piston, new sealing and spring.

Fig 67: Locating Accumulator Piston, Sealing And Spring

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Accumulator spring identification.

ACCUMULATOR SPRING IDENTIFICATION CHART

NO.	Use	I.D. Color	Number
A	U/D clutch	White/White	2
B	O/D clutch	Yellow	1
C	2ND brake	Yellow/Yellow	2
D	L/R brake	Yellow	1

Install the two new O-rings.
NOTE: Insert the new O-ring into the hole of the L/R brake and transfer driven gear.

Fig 68: Locating O-Rings
Courtesy of KIA MOTORS AMERICA, INC.
Install the valve body(Bolt:21EA).
NOTE: 6x30□(A): 17EA, 6x35□(B): 1EA, 6x40□(C): 1EA, 6x55□(D): 1EA, 6x60□(E): 1EA

TORQUE :

10~12Nm(100~120kgf.cm, 7~8lb-ft)

Fig 69: Locating Valve Body Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the manual valve mounting bracket(Nut:1EA)
TORQUE :

9~12Nm(90~120kgf.cm, 6.5~8lb-ft)

Fig 70: Locating Manual Valve Mounting Bracket Nut
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil filter(A) (Bolt:3EA).
TORQUE :

5~7Nm(50~70kgf.cm, 4~5lb-ft)

Fig 71: Locating Oil Filter And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the three magnets in the lower end of the oil filter.

Fig 72: Locating Magnets In Lower End Of Oil Filter
Courtesy of KIA MOTORS AMERICA, INC.
Apply liquid gasket with 0.102in(2.6mm) thickness without a pause as shown in the illustration.

Fig 73: Applying Liquid Gasket With 0.102in (2.6mm) Thickness
Courtesy of KIA MOTORS AMERICA, INC.
Connect the oil pan(A) and tighten the bolt.
TORQUE :

10~12Nm(100~120kgf.cm, 7~8lb-ft)

Fig 74: Locating Oil Pan And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the drain plug(A).
TORQUE :

35~45Nm(350~450kgf.cm, 25~32lb-ft)

Fig 75: Locating Drain Plug
Courtesy of KIA MOTORS AMERICA, INC.