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Reverse/Forward Clutch Assembly: Reassembly

  1. Install reverse clutch piston.
    1. Apply ATF to inner and outer faces of seals, and install them to reverse clutch piston.
    2. Insert reverse clutch piston by pushing evenly around circumference, being careful not to damage seal rings.
    Fig 1: Installing Reverse Clutch Piston
    G01079771Courtesy of KIA MOTORS AMERICA, INC.
  2. Install piston return spring with tabs facing away from reverse clutch piston.
  3. Install return spring stop with step facing upward.
    Fig 2: Installing Piston Return Spring
    G01079772Courtesy of KIA MOTORS AMERICA, INC.
  4. Install snap ring half-way down reverse/forward drum as shown.
    Fig 3: Installing Snap Ring Half-Way Down Reverse/Forward Drum
    G01079773Courtesy of KIA MOTORS AMERICA, INC.
  5. Install SST (0K201 190 AA1/K94A-4209-AT)  on reverse/forward drum.
  6. Compress spring and retainer assembly.
  7. Install snap ring with a screwdriver.
  8. Remove SST (0K201 190 AA1/K94A-4209-AT). 
    Fig 4: Removing Service Tool
    G01079774Courtesy of KIA MOTORS AMERICA, INC.
  9. Install dished plate with dished side facing downward into drum as shown.
  10. Install drive and driven plates (two of each).
    NOTE: Installation order: Driven-Drive-Driven-Drive
  11. Install retaining plate.
  12. Install snap ring.
    Fig 5: Installing Drive And Driven Plates
    G01079775Courtesy of KIA MOTORS AMERICA, INC.
  13. Measure reverse clutch clearance.
    1. Measure clearance between snap ring and retaining plate of reverse clutch.
    2. If clearance is not within specification, adjust it by selecting snap ring with correct thickness.

    Reverse clutch clearance: 0.035-0.047 in (0.9-1.2 mm) 

    Fig 6: Measuring Reverse Clutch Clearance
    G01079777Courtesy of KIA MOTORS AMERICA, INC.
    Fig 7: Reverse Clutch Snap Ring Size Chart
    G01079776Courtesy of KIA MOTORS AMERICA, INC.
  14. Install coasting clutch drum.
    1. Apply ATF to inner and outer faces of seal, and install it onto coasting clutch drum.
    2. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into drum.
      Fig 8: Positioning Coasting Drum Outer Seal
      G01079778Courtesy of KIA MOTORS AMERICA, INC.
    3. Install coasting clutch drum in correct position in reverse/forward drum as shown.
    4. Push evenly around circumference, being careful not to damage outer seal.
    Fig 9: Positioning Coasting Clutch Drum Into Reverse Drum
    G01079779Courtesy of KIA MOTORS AMERICA, INC.
  15. Install coasting clutch piston.
    1. Apply ATF to inner and outer faces of seals and install them onto coasting clutch piston.
    2. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into drum.
    Fig 10: Positioning Coasting Clutch Piston
    G01079780Courtesy of KIA MOTORS AMERICA, INC.
  16. Install spring and retainer assembly.
    Fig 11: Installing Coasting Clutch Spring And Retainer Assembly
    G01079781Courtesy of KIA MOTORS AMERICA, INC.
  17. Install SST (0K201 190 AA1/K94A-4207-AT)  in coasting clutch as shown.
  18. Compress spring and retainer assembly.
  19. Install snap ring.
  20. Remove SST (0K201 190 AA1/K94A-4207-AT). 
    Fig 12: Compressing Spring And Retainer Assembly
    G01079782Courtesy of KIA MOTORS AMERICA, INC.
  21. Install dished plate with dished side facing out of drum as shown.
  22. Install drive and driven plate.
    NOTE: Installation order: Driven-Drive-Driven-Drive
  23. Install retaining plate.
  24. Install snap ring.
    Fig 13: Installing Drive And Driven Plate
    G01079783Courtesy of KIA MOTORS AMERICA, INC.
  25. Measure coasting clutch clearance.
    1. Measure clearance between snap ring and retaining plate of coasting clutch.
    2. If clearance is not within specification, adjust it by selecting snap ring with correct thickness.
    1. Coasting clutch clearance: 0.039-0.048 in (1.0-1.2 mm) 
    Fig 14: Measuring Coasting Clutch Clearance
    G01079785Courtesy of KIA MOTORS AMERICA, INC.
    Fig 15: Coasting Clutch Snap Ring Size Chart
    G01079784Courtesy of KIA MOTORS AMERICA, INC.
  26. Install dished plate with dished side facing downward into drum, as shown.
  27. Install drive and driven plates.
    NOTE: Installation order: Driven-Drive-Driven-Drive-Driven-Drive
    Fig 16: Installing Drive And Driven Plates
    G01079786Courtesy of KIA MOTORS AMERICA, INC.
  28. Install retaining plate.
  29. Install snap ring.
    Fig 17: Installing Snap Ring
    G01079787Courtesy of KIA MOTORS AMERICA, INC.
  30. Measure forward clutch clearance.
    1. Measure clearance between snap ring and retaining plate of forward clutch.
    2. If clearance is not within specification, adjust it by selecting snap ring with correct thickness.

    Forward clutch clearance: 0.039-0.048 in (1.0-1.2 mm) 

    Fig 18: Measuring Forward Clutch Clearance
    G01079789Courtesy of KIA MOTORS AMERICA, INC.
    Fig 19: Forward Clutch Snap Ring Size Chart
    G01079788Courtesy of KIA MOTORS AMERICA, INC.
  31. Check clutch operation as follows:
    1. Set clutch assembly onto oil pump.
    2. Check clutch operation by applying compressed air though fluid passages shown.

    Air pressure: 57 psi (392 kPa, 4.0 kg/cm 2  ) maximum) 

    Fig 20: Checking Forward Clutch Operation
    G01079790Courtesy of KIA MOTORS AMERICA, INC.
  32. Apply petroleum jelly to thrust bearings, and secure them on each side of reverse/forward drum.
    1. Thrust bearing outer diameter: Oil pump side: 3.39 in (86.0 mm) 
    2. Small sun gear and one-way clutch side: 2.21 in (56.1 mm) 
    Fig 21: Securing Thrust Bearing Onto Reverse/Forward Drum
    G01079791Courtesy of KIA MOTORS AMERICA, INC.
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