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Home >> Kia >> 2008 >> Rio Base, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transaxle System >> Manual Transaxle >> Removal

Manual Transaxle: Removal

CAUTION:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE:
  • Mark all wiring and hoses to avoid mis-connection.
  1. Remove the battery (A) after removing the battery terminal.
    Fig 1: Battery
    G04862445Courtesy of KIA MOTORS AMERICA, INC.
  2. Remove the intake air hose and air cleaner assembly.
    1. Disconnect the air flow sensor connector (A).
    2. Disconnect the air cleaner hose (D) from the bleeder hose (B).
    3. Remove the intake air hose and air cleaner upper cover (C).
      Fig 2: Identifying Air Flow Sensor Connector, Bleeder Hose, Lower Cover And Air Cleaner Hose
      G04862446Courtesy of KIA MOTORS AMERICA, INC.
    4. Disconnect the ECM connector (A, B).
    5. Remove the air cleaner element and lower cover (C).
      Fig 3: ECM Connector And Lower Cover
      G04862447Courtesy of KIA MOTORS AMERICA, INC.
  3. Remove the battery tray (A).
    Fig 4: Battery Tray
    G04862448Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the ground cable from transaxle (A).
    Fig 5: Identifying Ground Cable From Transaxle
    G04862449Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the transaxle wire harness connectors and control cable from transaxle.
    1. Remove the clutch release cylinder (A).

      TORQUE: 15-22 N.m (150-220 kgf.cm, 10-16 lb.ft)

      Fig 6: Identifying Clutch Slave Bleeder Plug
      G04862407Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the transaxle control cable (A). A
      Fig 7: Identifying Transaxle Control Cable
      G04862451Courtesy of KIA MOTORS AMERICA, INC.
    3. Disconnect the vehicle speed sensor connector (A).
    4. Disconnect the back lamp switch connector (B).
      Fig 8: Back Lamp Switch Connector
      G04862452Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the power steering oil hose (A) and drain the power steering oil.
    Fig 9: Identifying Power Steering Oil Hose And Drain Power Steering Oil
    G04862453Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the power steering return hose (A).
    Fig 10: Identifying Power Steering Return Hose
    G04862454Courtesy of KIA MOTORS AMERICA, INC.
  8. Install the SST (09200-38001), the engine support fixture and the adapter on the engine and transaxle assembly.
    Fig 11: Identifying SST (09200-38001)
    G04862455Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the transaxle mounting support bracket (A).

    TORQUE: (B): 70-95 N.m (700-950 kgf.cm, 50-69 lb.ft)

    Fig 12: Identifying Transaxle Mounting Support Bracket
    G04862456Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the front roll stopper insulator bolt (A).

    TORQUE: 50-65 N.m (500-650 kgf.cm, 36-47 lb.ft)

    Fig 13: Identifying Front Roll Stopper Insulator Bolt
    G04862457Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the rear roll stopper insulator bolt (A).

    TORQUE: 50-65 N.m (500-650 kgf.cm, 36-47 lb.ft)

    Fig 14: Identifying Rear Roll Stopper Insulator Bolt
    G04862458Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the under cover (A).
    Fig 15: Identifying Under Cover
    G04862459Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the side cover.
  14. Remove the front tires.
  15. Remove the tie rod end (A) pin (B) and nut (C), then remove the tie rod end.
    Fig 16: Tie Rod End Pin And Nut
    G04862460Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the ABS wheel speed sensor (A).
    Fig 17: ABS Wheel Speed Sensor
    G04862461Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the caliper and hang caliper assembly (A).
    Fig 18: Removing Caliper
    G04862462Courtesy of KIA MOTORS AMERICA, INC.
    Fig 19: Suspending Caliper Assembly With Wire
    G04862463Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the knuckle mounting bolts.
  19. Remove the drive shaft from transaxle.
  20. Remove the steering U-joint mounting bolt.
  21. Using a floor jack, support the transaxle assembly.
    NOTE: After removing the sub frame mounting bolts, the transaxle assembly may fall downward, and so support them securely with floor jack.
    Verify that the hoses and connectors are disconnected before removing the transaxle assembly.
  22. Remove the sub frame.

    TORQUE:

    Bolt (A): 40-55 N.m (400-500 kgf.cm, 29-40 lb.ft)

    Nut (B): 160-180 N.m (1600-1800 kgf.cm, 116-130 lb.ft)

    Fig 20: Identifying Sub Frame Bolts
    G04862464Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the starter motor mounting bolts (A).

    TORQUE:

    27-34 N.m (270-340 kgf.cm, 19-24 lb.ft)

    Fig 21: Identifying Starter Motor Mounting Bolts
    G04862465Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the transaxle upper mounting bolts from engine.

    TORQUE:

    60-80 N.m (600-800 kgf.cm, 43-58 lb.ft)

  25. Remove the transaxle lower mounting bolts.

    TORQUE:

    Bolt (A): 15-22 N.m (150-220 kgf.cm, 10-16 lb.ft)

    Bolt (B): 43-55 N.m (430-500 kgf.cm, 32-40 lb.ft)

    Fig 22: Identifying Transaxle Lower Mounting Bolts
    G04862466Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the transaxle assembly by lifting vehicle.
    NOTE: When removing the transaxle assembly, be careful not to damage any surrounding parts or body components.
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