Manual Transaxle: Reassembly

Upon reassembly, see SERVICE TIP  and SERVICE POINTS  .

1. Install the drive shaft oil seal using the special tool (09431-21200).
   NOTE: Insert the oil seal straightly.
   Fig 1: Installing Drive Shaft Oil Seal

   Courtesy of KIA MOTORS AMERICA, INC.
2. Install the input shaft front oil seal using the special tool (09431-21000).
   CAUTION: Do not reuse the oil seal.
   Fig 2: Installing Input Shaft Front Oil Seal

   Courtesy of KIA MOTORS AMERICA, INC.
3. Install the output shaft oil guide.
   Fig 3: Installing Output Shaft Oil Guide

   Courtesy of KIA MOTORS AMERICA, INC.
4. Install the output shaft bearing outer race using the special tools (09500-11000, 9532-11500).
   Fig 4: Installing Output Shaft Bearing Outer Race

   Courtesy of KIA MOTORS AMERICA, INC.
5. Install the control shaft assembly.
   Fig 5: Identifying Control Shaft Assembly

   Courtesy of KIA MOTORS AMERICA, INC.
   1. After inserting the rubber boot onto the control shaft, insert the control shaft into the clutch housing.
      Fig 6: Installing Control Shaft & Rubber Boot

      Courtesy of KIA MOTORS AMERICA, INC.
   NOTE: Larger diameter of the neutral return spring (B) should be toward the side wall of the clutch housing as shown in figure.
   Fig 7: Installing Neutral Return Spring Onto Control Shaft
   Courtesy of KIA MOTORS AMERICA, INC.
   2. Insert the neutral return spring (B) onto the control shaft.
   NOTE: The lug on the control finger should point in the same direction as the control shaft lever.
   Fig 8: Assembling Control Finger & Inter Lock Plate
   Courtesy of KIA MOTORS AMERICA, INC.
   3. Slide the control finger inside the inter lock plate, and then slide the assembly onto the control shaft.
   4. Insert the stopper plate.
   5. Push the control shaft assembly into the clutch housing support hole.
   6. Push the lock pin through the control finger and control shaft.
   Fig 9: Identifying Neutral Return Spring

   Courtesy of KIA MOTORS AMERICA, INC.
6. Install the differential gear assembly.
   Fig 10: Installing Differential Gear Assembly

   Courtesy of KIA MOTORS AMERICA, INC.
7. Insert the output shaft, inclining the differential assembly, and insert the input shaft, inclining the output shaft.
   Fig 11: Installing Input Shaft & Output Shaft

   Courtesy of KIA MOTORS AMERICA, INC.
CAUTION: Apply a THREE BOND 1303 on the hex-bolts.
Fig 12: Installing Input Shaft Bearing Retainer
Courtesy of KIA MOTORS AMERICA, INC.
8. Install the input shaft bearing retainer.
9. Reassembly of the shift rail assemblies:
   1. Place the first and second speed synchronizer sleeve to the second gear position in order to get installing space of 1st-2nd shift rail assembly.
   2. Place the third and fourth speed synchronizer sleeve to neutral position.
   3. Install the shift rail and fork assemblies.
   Fig 13: Reassembling Shift Rail Assemblies

   Courtesy of KIA MOTORS AMERICA, INC.
10. Reassembly of spring pin:
    CAUTION: Do not reuse the spring pin.
    Fig 14: Identifying Spring Pins
    Courtesy of KIA MOTORS AMERICA, INC.
    Fig 15: Installing Spring Pin (1 Of 2)
    Courtesy of KIA MOTORS AMERICA, INC.
    1. Install the spring pins using the special tool (09414-11000) or pin punch.
    2. When installing, make sure that the slit of the spring pin is aligned with center line of the shift rail.
       Fig 16: Installing Spring Pin (2 Of 2)

       Courtesy of KIA MOTORS AMERICA, INC.
11. Install the reverse gear shaft and reverse gear.
    Fig 17: Installing Reverse Gear Shaft And Reverse Gear

    Courtesy of KIA MOTORS AMERICA, INC.
12. Install the reverse shift lever.
    Fig 18: Installing Reverse Shift Lever

    Courtesy of KIA MOTORS AMERICA, INC.
CAUTION: Do not reuse the oil seal.
Fig 19: Installing Drive Shaft Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
13. Install the drive shaft oil seal in the transaxle case using the special tool (09431-21200).
14. Install the input shaft bearing outer race and spacer using the special tools (09432-22100/09500-11000).
15. Install the output shaft bearing outer race and spacer using the special tools (09432-22100/09500-11000).
    Fig 20: Installing Outer Race & Spacer

    Courtesy of KIA MOTORS AMERICA, INC.
16. Installation of spacer:
    1. Place two pieces of rosin-core solder with 3 mm (0.118 in.) in diameter on the bearing outer race as illustrated.
       Fig 21: Installing Spacer (1 Of 4)

       Courtesy of KIA MOTORS AMERICA, INC.
    2. Install the transaxle case temporarily and tighten the bolts to the specified torque, then remove the transaxle case.
       Fig 22: Installing Spacer (2 Of 4)

       Courtesy of KIA MOTORS AMERICA, INC.
       Fig 23: Installing Spacer (3 Of 4)

       Courtesy of KIA MOTORS AMERICA, INC.
    3. Detach the crushed solders.
       Fig 24: Installing Spacer (4 Of 4)

       Courtesy of KIA MOTORS AMERICA, INC.
    4. Measure the thickness of the crushed solder.
       Fig 25: Measuring Thickness Of Crushed Solder

       Courtesy of KIA MOTORS AMERICA, INC.
    5. Select and install the proper spacers.
       Fig 26: Selecting Proper Spacers

       Courtesy of KIA MOTORS AMERICA, INC.

       SELECTION EXAMPLE

       • Output shaft
         1. The thickness of the crushed solder : 1.72 mm (0.0677 in.)
         2. Standard value : 0.07T mm (0.0002 in.) 1.72 mm (0.0677 in.) + 0.07 mm (0.0027 in.) = 1.79 mm (0.0704 in.). Therefore, select the spacer of the 1.79 mm (0.0704 in.) thickness.
17. Install the oil guide in the transaxle case.
    Fig 27: Installing Oil Guide

    Courtesy of KIA MOTORS AMERICA, INC.
18. Apply the specified sealant to the clutch housing side of the transaxle case.

    Specified sealant: THREE BOND 1216

19. Install the transaxle case onto the clutch housing assembly and tighten the bolts.

    Tightening torque 

    Transaxle case: 35~42 Nm (350~420 kg.cm, 26~31 lb. ft)

    Fig 28: Installing Transaxle Case Onto Clutch Housing Assembly

    Courtesy of KIA MOTORS AMERICA, INC.
20. Center the reverse idler gear shaft with screw driver.
    Fig 29: Centering Reverse Idler Gear Shaft With Screw Driver

    Courtesy of KIA MOTORS AMERICA, INC.
21. Tighten the reverse idler gear shaft bolt to the specified torque.

    Reverse gear shaft bolt tightening torque: 

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

22. Install the 5th-reverse shift rail poppet bolt. See SERVICE TIP .
    Fig 30: Installing 5th-Reverse Shift Rail Poppet Bolt

    Courtesy of KIA MOTORS AMERICA, INC.
23. Install the output shaft gear using the special tool (09432-33300).
    Fig 31: Installing Output Shaft Gear

    Courtesy of KIA MOTORS AMERICA, INC.
24. Install the rear bearing, spacer, snap ring and 5th gear sleeve.
    Fig 32: Installing 5th Gear Sleeve

    Courtesy of KIA MOTORS AMERICA, INC.
CAUTION: Place the oil groove of synchronizer hub toward the fifth speed gear.
Fig 33: Installing 5th Gear
Courtesy of KIA MOTORS AMERICA, INC.
25. Install the fifth speed gear, needle roller bearing, synchronizer ring and synchronizer hub.
26. Install the stopper plate.
    Fig 34: Installing Stopper Plate

    Courtesy of KIA MOTORS AMERICA, INC.
27. Install the race.
    Fig 35: Installing Race

    Courtesy of KIA MOTORS AMERICA, INC.
28. Install the 5th shift fork and the 5th synchronizer sleeve at the same time.
    Fig 36: Installing 5th Shift Fork And 5th Synchronizer Sleeve

    Courtesy of KIA MOTORS AMERICA, INC.
29. Reassembly of locking nut:
    1. Shift the transaxle into 3rd and 5th gear.
    2. Tighten the locking nut to the specified torque.

       Tightening torque: 

       140~160 Nm (1400~1600 kg.cm, 102~115 lb. ft)

       Fig 37: Tightening The Locking Nut

       Courtesy of KIA MOTORS AMERICA, INC.
    3. Stake the locking nut.
       Fig 38: Staking The Locking Nut

       Courtesy of KIA MOTORS AMERICA, INC.
CAUTION: Do not reuse the spring pin.
Fig 39: Installing Spring Pin (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
30. Install the spring pin using the special tool (09414-11000) or pin punch.
31. When installing, make sure that the slit of the spring pin is aligned with the center line of the shift rail.
    Fig 40: Installing Spring Pin (2 Of 2)

    Courtesy of KIA MOTORS AMERICA, INC.
32. Apply the specified sealant to the rear cover and install the rear cover.

    Specified sealant : THREE BOND 1216

    Fig 41: Applying Sealant To Rear Cover

    Courtesy of KIA MOTORS AMERICA, INC.
33. Install the rear cover bolts (A) (8EA) and the rear cover (B).
    Fig 42: Installing Rear Cover Bolts And Rear Cover

    Courtesy of KIA MOTORS AMERICA, INC.
34. Install the speedometer driven gear assembly.

    Speedometer driven gear tightening torque: 

    3~5 Nm (30~50 kg.cm, 2~4 lb. ft)

35. Install the backup light switch.

    Backup light switch tightening torque: 

    30~35 Nm (300~350 kg.cm, 22~25 lb. ft)

36. Install the shift cable bracket (A).
    Fig 43: Installing Shift Cable Bracket

    Courtesy of KIA MOTORS AMERICA, INC.