Transaxle Reassembly: Reassembly

Align bush cover with guide bolts as shown in figure and press it in.
Tightening torque:

96~120 lb. in (10.8~13.7 N.m, 110~140 kg.cm)

Fig 1: Pressing In Bush Cover
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 And Output Gear
  Courtesy of KIA MOTORS AMERICA, INC.
2. Align grove 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. ft (19~25 N.m, 1.9~2.6 kg.m)

Fig 3: Tightening 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. ft (15~17 N.m, 1.5~1.8 kg.m)

Fig 5: Installing Actuator Support
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
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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
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. ft (42~5.6 kg.m)

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 surface of converter housing and transaxle case.
Install new O-rings onto converter housing.
NOTE: Insure that sealer will not be forced into oil passages when transaxle case is installed.
Mount transaxle case to converter housing.
Tightening torque:

28~38 lb. ft (38~51 N.m, 3.8~5.3 kg.m)

Fig 11: Mounting Transaxle Case To Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Install SST (0K201 190 019) to hold turbine shaft.

Fig 12: Holding Turbine Shaft With Service Tool
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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: Installing Turbine Shaft And 3-4 Clutch Assembly
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: Installing Planetary Carrier Assembly
  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: Holding Turbine Shaft With One Hand To Prevent It From Rotating
Courtesy of KIA MOTORS AMERICA, INC.
Install low and reverse brake drive and driven plates (four each).
NOTE: Plate 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
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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 figure.

Fig 21: Interlocking 2-4 Brake Band And Anchor
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 That Thrust Bearing And Bearing Race Are Installed In Correct Position
  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: Installing Reverse/Forward Clutch Assembly
  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
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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:
1. Set thrust bearing onto reverse/forward clutch assembly
  
  Fig 28: Setting Thrust Bearing Onto Reverse/Forward Clutch Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove previously used race and gasket.
3. Set thickest bearing race 0.087 in (2.2 mm) onto oil pump.
4. Set oil pump onto clutch assembly.
  NOTE: Do not install oil pump gasket at this time.
  
  Fig 29: Setting Thickest Bearing Race 0.087 In. (2.2 Mm) Onto Oil Pump
  Courtesy of KIA MOTORS AMERICA, INC.
5. Measure clearance (A) between transaxle case and oil pump.
6. Select a suitable bearing race from chart shown in figure.
  
  Fig 30: Measuring Clearance (A) Between Transaxle Case And Oil Pump
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 31: Illustrating Bearing Race Chart
  Courtesy of KIA MOTORS AMERICA, INC.
7. Remove oil pump.
8. Place selected bearing race and a new gasket onto oil pump.
9. Install oil pump onto transaxle assembly.
  Tightening torque:
  
  14~18 lb. ft (19~25 N.m, 190~260 kg.cm)
Fig 32: Installing Oil Pump Onto Transaxle Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Verify 2-4 brake band adjustment as follows:
1. Install servo piston to SST (0K201 190 021).
2. Install servo retainer O-ring onto SST (0K201 190 021).
3. Coat O-ring with ATF, install band servo assembly and SST into transaxle case and secure it with snap ring.
  
  Fig 33: Installing Band Servo Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Insure that 2-4 brake band is correctly positioned against band servo piston stem.
4. Set a dial indicator against piston stem.
  
  Fig 34: Setting A Dial Indicator Against Piston Stem
  Courtesy of KIA MOTORS AMERICA, INC.
5. Apply compressed air through fluid passage with a rubber-tipped air nozzle as shown in figure 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 35: Pressurizing Band Servo Fluid Passage & Measuring Piston Stem Stroke
  Courtesy of KIA MOTORS AMERICA, INC.
6. If not within specification, select proper piston stem as shown in figure.
  
  Fig 36: Piston Stem Length Chart
  Courtesy of KIA MOTORS AMERICA, INC.
7. 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.
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 37: Installing Control Valve Body
Courtesy of KIA MOTORS AMERICA, INC.
Connect solenoid valve and ATF temperature sensor connectors.
Connect solenoid connector.

Fig 38: Connect Solenoid Connectors
Courtesy of KIA MOTORS AMERICA, INC.

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

Fig 39: Attaching Magnets Inside Oil Pan
Courtesy of KIA MOTORS AMERICA, INC.
Install a new gasket and oil pan tighten 19 bolts.
Tightening torque:

74.4-94.8 lb. in (8.4~10.7 N.m, 80~110 kg.cm)
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 (0K 130 990 007/0K130 175 011 A).
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 A New O-Ring Onto Turbine Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Fill torque converter with ATF.
ATF type: SK ATF SP-III or DIAMOND ATF SP-III
NOTE:
- Hold torque converter in an upright position when filling it with ATF. Do not allow fluid to overflow.
- If converter does not fit in easily, do not try to force it: install carefully.
- Do not damage O-ring onto turbine shaft.
Install torque converter in converter housing while rotating it to align splines.

Fig 41: Installing Torque Converter In Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
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 42: Measuring Converter Position
Courtesy of KIA MOTORS AMERICA, INC.