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Manual Transaxle: Disassembly

  1. Remove the control and select cable bracket (A).
    Fig 1: Identifying Control & Select Cable Bracket
    G00333201Courtesy of KIA MOTORS AMERICA, INC.
  2. Remove the backup light switch.
    Fig 2: Removing Backup Light Switch
    G00333202Courtesy of KIA MOTORS AMERICA, INC.
  3. Remove the rear cover bolts (A) and the rear cover (B).
    Fig 3: Identifying Rear Cover Bolts And Rear Cover
    G00333203Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the spring pin of the fifth speed shift fork using the special tool (09414-11000).
    Fig 4: Removing Fifth Speed Shift Fork Spring Pin
    G00333204Courtesy of KIA MOTORS AMERICA, INC.
  5. To remove the locking nuts of input shaft and output shaft, unstake the locking nuts.
    Fig 5: Identifying Input Shaft And Output Shaft Locking Nuts
    G00333205Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove and discard the locking nuts of input shaft and output shaft.
    Fig 6: Removing Input Shaft And Output Shaft Locking Nuts
    G00333206Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the race.
    Fig 7: Identifying Race
    G00333207Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the stopper plate.
    Fig 8: Identifying Stopper Plate
    G00333208Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the fifth synchronizer sleeve and the 5th shift fork.
    Fig 9: Identifying Fifth Synchronizer Sleeve And Fifth Shift Fork
    G00333209Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the fifth synchronizer hub, the ring with fifth speed gear and the needle roller bearing using the special tool (09495-33000).
    Fig 10: Removing Fifth Synchronizer Hub, Ring With Fifth Speed Gear And Needle Roller Bearing
    G00333210Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the fifth speed gear after removing the locking nut on the output shaft using the special tool (09495-33000).
    Fig 11: Removing Fifth Speed Gear
    G00333211Courtesy of KIA MOTORS AMERICA, INC.
    Fig 12: Identifying Fifth Speed Gear
    G00333212Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the fifth speed gear sleeve and race.
    Fig 13: Removing Fifth Speed Gear Sleeve
    G00333213Courtesy of KIA MOTORS AMERICA, INC.
    Fig 14: Removing Race
    G00333214Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the reverse gear shaft bolt.
    Fig 15: Removing Reverse Gear Shaft Bolt
    G00333215Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the fifth and reverse shift rail poppet bolt.
    Fig 16: Removing Fifth & Reverse Shift Rail Poppet Bolt
    G00333216Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the transaxle case mounting bolts (14EA), and then the transaxle case.
    Fig 17: Removing Transaxle Case Mounting Bolts (14EA) And Transaxle Case
    G00333217Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the oil guide.
    Fig 18: Removing Oil Guide
    G00333218Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the output shaft bearing outer race and the spacer.
    Fig 19: Removing Output Shaft Bearing Outer Race And Spacer (1 Of 2)
    G00333219Courtesy of KIA MOTORS AMERICA, INC.
    Fig 20: Removing Output Shaft Bearing Outer Race And Spacer (2 Of 2)
    G00333220Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the reverse shift lever.
    Fig 21: Removing Reverse Shift Lever
    G00333221Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the reverse gear shaft and gear.
    20. CAUTION: Be careful not to damage it when removing 1st-2nd spring pin.
    Fig 22: Removing Spring Pin Of 3rd-4th Gear Shift Fork
    G00333222Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the spring pin of 3rd-4th gear shift fork.
  21. Remove the shift rail and fork for 3rd-4th and 5th-Rev.
    Fig 23: Removing Shift Rail & Fork For 3rd-4th And 5th-Rev
    G00333223Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the shift rail and fork for 1st-2nd.
    Fig 24: Removing Shift Rail & Fork For 1st-2nd
    G00333224Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the bearing retainer.
    Fig 25: Removing Bearing Retainer
    G00333225Courtesy of KIA MOTORS AMERICA, INC.
  24. Pull out the input shaft from the clutch housing, inclining the output shaft.
    Fig 26: Removing Input Shaft & Output Shaft From Clutch Housing
    G00333226Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the differential gear assembly.
    Fig 27: Identifying Differential Gear Assembly
    G00333227Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the speedometer driven gear assembly.
    Fig 28: Identifying Speedometer Driven Gear Assembly
    G00333228Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the output shaft bearing outer race.
    Fig 29: Removing Output Shaft Bearing Outer Race
    G00333229Courtesy of KIA MOTORS AMERICA, INC.
  28. Remove the oil seal.
    Fig 30: Removing Oil Seal
    G00333230Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the output shaft oil guide.
    Fig 31: Removing Output Shaft Oil Guide
    G00333231Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the input shaft oil seal.
    Fig 32: Removing Input Shaft Oil Seal
    G00333232Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the control shaft assembly.
    Fig 33: Identifying Control Shaft Assembly
    G00333233Courtesy of KIA MOTORS AMERICA, INC.
    1. Remove the bolt (12 mm (0.47 in.) - 1EA) which is installed to the rear portion of clutch housing.
      Fig 34: Identifying Bolt In Rear Portion Of Clutch Housing
      G00333234Courtesy of KIA MOTORS AMERICA, INC.
    2. Using the special tool (09414-11000), remove the lock pin.
      NOTE: When removing the control shaft, the lock pin should be removed first.
      Fig 35: Removing Control Shaft Lock Pin
      G00333235Courtesy of KIA MOTORS AMERICA, INC.
    3. While holding and twisting the control shaft by hand, pull the control shaft out of its position.
      Fig 36: Removing Control Shaft
      G00333236Courtesy of KIA MOTORS AMERICA, INC.
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