Transaxle Reassembly: Reassembly

WARNING: This page is about a different variant/trim than selected.

NOTE: For exploded views of components, refer to COMPONENTS .

Align bush cover with guide bolts as shown in illustration, and press it in.
Tightening torque: 96 ~120 lb. in. (10.8~13.7 N.m, 110~140 kg.cm)

Fig 1: Aligning Bush Cover With Guide Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install idler gear and output gear as an assembly by tapping it with a plastic hammer.
Install bearing housing.
1. Install bearing housing on converter housing.
  
  Fig 2: Installing Idler Gear & Output Gear
  Courtesy of KIA MOTORS AMERICA, INC.
2. Align groove on idler shaft with mark on bearing housing.
3. Tap a new roll pin in with a pin punch and hammer.
4. Install 11 mounting bolts.
  Tightening torque: 14~18 lb. in. (19~25 N.m, 1.9~2.6 kg.m)
  
  Fig 3: Installing Mounting Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
Install parking pawl.
1. Install parking pawl and shaft.
2. Install spring and snap ring.
3. Move manual shaft and verify that parking pawl operates.
Fig 4: Installing Parking Pawl And Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Install actuator support with new bolts.
Tightening torque: 11~13 lb. in. (15~17 N.m, 1.5~1.8 kg.m)

Fig 5: Installing Actuator Support With New Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install detent lever and return spring.

Fig 6: Installing Detent Lever And Return Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install parking assist lever.

Fig 7: Installing Parking Assist Lever
Courtesy of KIA MOTORS AMERICA, INC.
Install lever holder and bolt.
Tightening torque: 69.6~94.8 lb. in. (7.9 ~10.7 N.m, 80~110 kg.cm)

Fig 8: Installing Lever Holder And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install manual shaft and manual plate.
1. Install manual plate, washer, and nut.
2. Tighten nut to specified torque.
  Tightening torque: 31~40 lb. in. (42~54 N.m, 4.2~5.6 kg.cm)
  
  Fig 9: Installing Manual Shaft And Manual Plate
  Courtesy of KIA MOTORS AMERICA, INC.
Install differential assembly into converter housing.
Install SST (0K201 270 014) or equivalent.
Install a new oil control ring onto output gear assembly.
Install output shell to output gear and install bearing race onto output shell.
Thrust bearing outer diameter: 2.84 in. (72.1 mm)

Fig 10: Installing Output Shell To Output Gear
Courtesy of KIA MOTORS AMERICA, INC.
Apply a thin coat of silicone sealant (TB-1217B) to contact surfaces of converter housing and transaxle case.
Install new O-rings onto converter housing.
NOTE: Ensure that sealer will not be forced into oil passages when transaxle case is installed.

Fig 11: Applying Sealant To Contact Surfaces Of Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Mount transaxle case to converter housing.
Tightening torque: 28~38 lb. in. (38~51 N.m, 3.8~5.3 kg.m)
Install SST (0K201 190 019) to hold turbine shaft.

Fig 12: Installing SST To Hold Turbine Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Install turbine shaft and 3-4 clutch assembly.
1. Assemble turbine shaft and 3-4 clutch assembly.
  
  Fig 13: Assembling Turbine Shaft And 3-4 Clutch Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
2. Verify that thrust bearing is properly installed.
3. Install turbine shaft and 3-4 clutch assembly into transaxle case as an assembly.
Fig 14: Verifying Thrust Bearing Installation
Courtesy of KIA MOTORS AMERICA, INC.
Install internal gear.
1. Install internal gear to output shell.
2. Install snap ring.
  
  Fig 15: Installing Internal Gear To Output Shell
  Courtesy of KIA MOTORS AMERICA, INC.
Install planetary carrier assembly.
1. Verify that thrust bearing and bearing race are properly installed.
  
  Fig 16: Verifying Thrust Bearing & Race Installation
  Courtesy of KIA MOTORS AMERICA, INC.
2. Hold turbine shaft with one hand to prevent it from rotating.
3. Install planetary carrier assembly into 3-4 clutch drum by rotating it.
  
  Fig 17: Installing Planetary Carrier Assembly Into 3-4 Clutch Drum
  Courtesy of KIA MOTORS AMERICA, INC.
Install low and reverse brake drive and driven plates (four each).
NOTE: Installation order: Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive

Fig 18: Installing Low And Reverse Brake Drive And Driven Plates
Courtesy of KIA MOTORS AMERICA, INC.
Install retaining plate.

Fig 19: Installing Retaining Plate
Courtesy of KIA MOTORS AMERICA, INC.
Install snap ring.
Install friction plate.
Install one-way clutch No. 2.
1. Hold one-way clutch No. 2 horizontally.
2. Install it by turning planetary carrier counterclockwise.
3. Install snap ring.
  
  Fig 20: Installing Snap Ring
  Courtesy of KIA MOTORS AMERICA, INC.
Install anchor strut and shaft.
NOTE: Interlock 2-4 brake band and anchor strut as shown in illustration.

Fig 21: Installing 2-4 Brake Band And Anchor Strut
Courtesy of KIA MOTORS AMERICA, INC.
Install 2-4 brake band in transaxle case so that it is fully expanded.

Fig 22: Installing 2-4 Brake Band In Transaxle Case
Courtesy of KIA MOTORS AMERICA, INC.
Install small sun gear and one-way clutch No. 1.
1. Verify that thrust bearing and bearing race are installed in correct position.
  
  Fig 23: Verifying Thrust Bearing And Bearing Race Installation
  Courtesy of KIA MOTORS AMERICA, INC.
2. Install small sun gear and one-way clutch No. 1 while rotating it.
  
  Fig 24: Installing Small Sun Gear And One-Way Clutch No 1
  Courtesy of KIA MOTORS AMERICA, INC.
Install reverse/forward clutch assembly.
1. Verify that thrust bearing is installed in correct position.
  
  Fig 25: Verifying Thrust Bearing Installation
  Courtesy of KIA MOTORS AMERICA, INC.
2. Install reverse/forward clutch assembly while rotating it.
NOTE: Measure height difference between reverse/forward drum and transaxle case.
Maximum: 0.035 in. (0.9 mm)

Fig 26: Measuring Height Difference Between Reverse/Forward Drum And Transaxle Case
Courtesy of KIA MOTORS AMERICA, INC.
Install snap ring into bottom ring groove of turbine shaft.

Fig 27: Installing Snap Ring Into Bottom Ring Groove Of Turbine Shaft
Courtesy of KIA MOTORS AMERICA, INC.

Measure total end play select a suitable bearing race as follows:

Set thrust bearing onto reverse/forward clutch assembly

Fig 28: Setting Thrust Bearing Onto Reverse/Forward Clutch Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Remove previously used race and gasket.
Set thickest bearing race 0.087 in. (2.2 mm) onto oil pump.
Set oil pump onto clutch assembly.
NOTE: Do not install oil pump gasket at this time.

Fig 29: Installing Thickest Bearing Race Onto Oil Pump
Courtesy of KIA MOTORS AMERICA, INC.
Measure clearance (A) shown in illustration between transaxle case and oil pump.

Select a suitable bearing race from following table.

BEARING RACE CLEARANCE SPECIFICATION

Clearance (A) in (mm)	Select this bearing race in (mm)
0.0.3~0.043 (0.091~1.10)	0.047 (1.2)
0.028~0.035 (0.71~0.90)	0.055 (1.4)
0.020~0.027 (0.51~0.70)	0.063 (1.6)
0.012~0.019 (0.31~0.50)	0.071 (1.8)
0.004~0.011 (0.11~0.30)	0.079 (2.0)
0~0.003 (0~0.10)	0.087 (2.2)

Fig 30: Measuring Clearance Between Transaxle Case And Oil Pump

Courtesy of KIA MOTORS AMERICA, INC.

Remove oil pump.
Place selected bearing race and a new gasket onto oil pump.
Install oil pump onto transaxle assembly.
Tightening torque: 14~18 lb. in. (19~25 N.m, 190~260 kg.cm)

Fig 31: Tightening Oil Pump Bolts
Courtesy of KIA MOTORS AMERICA, INC.

Verify 2-4 brake band adjustment as follows:

Install servo piston to SST (0K201 190 021)
Install servo retainer O-ring onto SST (0K201 190 021)
Coat O-ring with ATF, install band servo assembly and SST into transaxle case and secure it with snap ring.

Fig 32: Installing Servo Retainer O-Ring Onto Transaxle Case
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Ensure that 2-4 brake band is correctly positioned against band servo piston stem.
Set a dial indicator against piston stem.

Fig 33: Setting Dial Indicator Against Piston Stem
Courtesy of KIA MOTORS AMERICA, INC.
Apply compressed air through fluid passage with a rubber-tipped air nozzle as shown in illustration and measure piston stem stroke.
Air pressure: 57 psi (392 kPa, 4.0 kg/cm² ) maximum Stroke: 0.039~0.067 in. (1.0~1.7 mm)

Fig 34: Applying Compressed Air Through Fluid Passage With A Rubber-Tipped Air Nozzle
Courtesy of KIA MOTORS AMERICA, INC.

If not within specification, select proper piston stem from following table.

PISTON STEM LENGTH SPECIFICATION

Piston stem length in (mm)
3.740 (95.0)	3.760 (95.5)	3.780 (96.0)
3.799 (96.5)	3.819 (97.0)	3.389 (97.5)
3.868 (98.0)	3.878 (98.5)	3.898 (99.0)

Remove band servo assembly and remove SST.
NOTE: Do not deform snap ring when removing it.

Install servo into transaxle case
1. Install servo spring and servo assembly.
2. Install snap ring.
3. Position 2-4 brake band onto band servo piston stem.
  
  Fig 35: Installing Servo Into Transaxle Case
  Courtesy of KIA MOTORS AMERICA, INC.
Align manual valve with pin on manual plate and install control valve body.
Tightening torque: 69.6~94.8 lb. in. (7.9~10.7 N.m, 80~110 kg.cm) Bolt length: (measured from below the head) A: 1.18 in. (30 mm) B: 1.97 in. (50 mm) C: 0.55 in. (14 mm)

Fig 36: Installing Control Valve Body
Courtesy of KIA MOTORS AMERICA, INC.
Connect solenoid valve and ATF temperature sensor connectors.
Connect solenoid connector.

Fig 37: Connecting Solenoid Connectors
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Attach magnets inside oil pan in positions shown on illustration (in oil pan).

Fig 38: Attaching Magnets Inside Oil Pan In Positions
Courtesy of KIA MOTORS AMERICA, INC.
Install a new gasket and oil pan bolts (19).
Tightening torque: 74.4~94.8 lb. in. (8.4~10. 7 N.m, 80~110 kg.cm)

Fig 39: Installing Gasket And Oil Pan Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install inlet pipe and outlet pipe.
Install driven gear and vehicle speed sensor.
Install crankshaft position sensor.
Install bracket and select bracket.
Install transaxle range switch.
1. Turn manual shaft to N position.
2. Install transaxle range switch.
3. Tighten transaxle range switch mounting bolts.
  Tightening torque: 70~95 lb. in. (7.9~10.7 N.m, 80~110 kg.cm)
4. Verify that the selector lever range position and transaxle range switch correspond.
Remove transaxle from SST (0K130 990 007/0K130 175 011A).
Install a new O-ring and install oil level gauge and oil filler tube to transaxle case.
Tightening torque: 69.6~94.8 lb. in. (7.9~10.7 N.m, 80~110 kg.cm)
Install input/turbine speed sensor.
Tightening torque: 69.6~94.8 lb. in. (7.9~10.7 N.m, 80~110 kg.cm)
Install oil pump shaft.
Install a new O-ring onto turbine shaft.

Fig 40: Installing O-Ring Onto Turbine Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Fill torque converter with ATF.
ATF type: SK ATF SP-III
NOTE:
1. Hold torque converter in an upright position when filling it with ATF. Do not allow fluid to overflow.
2. If converter does not fit in easily, do not try to force it: install carefully.
3. Do not damage O-ring onto turbine shaft.
Install torque converter in converter housing while rotating it to align splines.
To ensure that the torque converter is installed accurately, measure distance "A" between face of torque converter and mounting surface of converter housing.
Distance (A): 0.535 in. (13.6 mm)

Fig 41: Installing Torque Converter
Courtesy of KIA MOTORS AMERICA, INC.

Fig 42: Measuring Distance "A" Between Face Of Torque Converter And Mounting Surface Of Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.