Automatic Transaxle: Disassembly

CAUTION:

Automatic transaxles consist of delicate parts. Be careful not to damage them in disassembly and assembly.
Spread a rubber mat on a workbench and keep it clean.
Do not use cotton or muslin fiber. Use nylon fabric or paper towel.
Cleanse the disassembled components. Clean metal parts with a general cleaning agent or dry them with a blower.
Clean clutch discs, thrust plates made of resin, and rubber parts with automatic transaxle fluid and keep them dust free.
If transaxle body has been damaged, disassemble and clean cooler system.

Remove the torque converter.

Fig 1: Identifying Torque Converter
Courtesy of KIA MOTORS AMERICA, INC.
Remove each bracket.
Remove the wiring harness bracket.
Remove the oil pan (A) (Bolt:19 EA).

Fig 2: Identifying Oil Pan & Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil filter (A) (Bolt:3 EA).

Fig 3: Identifying Oil Filter & Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the valve body (Bolt:21 EA).
NOTE: 6x30 mm(A): 17EA, 6x35 mm(B): 1EA, 6x40 mm(C) 1EA, 6X55 mm(D):1EA, 6x60 mm(E): 1EA

Fig 4: Identifying Valve Body Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the two O-rings from low & reverse brake and transfer drive gear hole.

Fig 5: Locating O-Rings
Courtesy of KIA MOTORS AMERICA, INC.

Remove each accumulator piston, a new seal ring and the springs.

NOTE: Accumulator spring identification

ACCUMULATOR SPRING IDENTIFICATION

NO.	Use	I.D. Color	Spring number
1	U/D clutch	White/ White	2
2	O/D clutch	Yellow	1
3	2ND brake	White	2
4	L/R brake	Yellow	1

Fig 6: Identifying Accumulator Piston, Seal Ring And Springs

Courtesy of KIA MOTORS AMERICA, INC.

Remove the control valve connector (A) and mounting clip (B).

Fig 7: Identifying Control Valve Connector And Mounting Clip
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil level gauge (A) and bracket (Bolt:2EA).

Fig 8: Identifying Oil Level Gauge With Bracket Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the shift cable bracket (A) (Bolt:2EA).

Fig 9: Identifying Shift Cable Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the plug (A) (Bolt: 1EA).

Fig 10: Identifying Plug
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Remove the output shaft speed senor (A) (Bolt:1 EA).

Fig 11: Identifying Output Shaft Speed Senor
Courtesy of KIA MOTORS AMERICA, INC.
Remove the input shaft speed senor (A) (Bolt:1 EA).

Fig 12: Identifying Input Shaft Speed Senor
Courtesy of KIA MOTORS AMERICA, INC.
Remove the torque converter housing (Bolt:17EA).

Fig 13: Identifying Torque Converter Housing Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil separate (A) (Bolt:3EA).

Fig 14: Identifying Oil Separator
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil seal (A) from the torque converter housing.

Fig 15: Identifying Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Remove the differential gear assembly (A).

Fig 16: Identifying Differential Gear Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Using the special tool (09453-2F100), remove the differential outer race (A).

Fig 17: Identifying Differential Outer Race
Courtesy of KIA MOTORS AMERICA, INC.
Remove the two O-rings.

Fig 18: Locating O-Rings
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump (A) (Bolt:7EA).
CAUTION: Do not disassemble the oil pump. Misalignment during assembly may damage the pump and the transaxle.

Fig 19: Identifying Oil Pump
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump gasket (A).

Fig 20: Identifying Oil Pump Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust washer (A).

Fig 21: Identifying Thrust Washer
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Remove the underdrive clutch (A).

Fig 22: Identifying Underdrive Clutch
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Remove the thrust bearing (A).

Fig 23: Identifying Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the underdrive clutch hub (A).

Fig 24: Identifying Underdrive Clutch Hub
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil guide plate (A).

Fig 25: Identifying Oil Guide Plate
Courtesy of KIA MOTORS AMERICA, INC.
Remove the parking rod guide (A) and the oil plate (B) ( Bolt:2EA).

Fig 26: Identifying Parking Rod Guide And Oil Plate
Courtesy of KIA MOTORS AMERICA, INC.
Remove the inhibitor switch (A) and the manual control lever (B).
(Inhibitor switch-Bolt:2EA, control lever shaft-Nut: 1EA).

Fig 27: Identifying Inhibitor Switch And Manual Control Lever
Courtesy of KIA MOTORS AMERICA, INC.
Remove the parking sprag (A), shaft (B) and sprag spring (C).

Fig 28: Identifying Parking Sprag, Shaft And Sprag Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the driven gear and the outer race.
Remove the plate (A) (1 reamer bolt).

Fig 29: Identifying Plate
Courtesy of KIA MOTORS AMERICA, INC.
Remove the detent spring (A).

Fig 30: Identifying Detent Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the manual shaft mounting groove bolt.

Fig 31: Identifying Manual Shaft Mounting Groove Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the reamer bolt from the detent lever.
Remove the manual control shaft (A) (including the two O-rings), the detent lever (B) and the parking rod (C).

Fig 32: Identifying Manual Control Shaft, Detent Lever And Parking Rod
Courtesy of KIA MOTORS AMERICA, INC.
Remove the feed tube (A) (4 gaskets, 2 eye bolts).

Fig 33: Identifying Feed Tube
Courtesy of KIA MOTORS AMERICA, INC.
Remove the rear cover (A) ( Bolt:9EA).

Fig 34: Identifying Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the five O-rings from the transaxle.

Fig 35: Identifying O-Rings
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust race (A) from the rear cover.

Fig 36: Identifying Thrust Race
Courtesy of KIA MOTORS AMERICA, INC.
Remove the four seal rings from the rear cover.

Fig 37: Identifying Seal Rings On Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust bearing (45851-23000).

Fig 38: Identifying Thrust Bearing (45851-23000)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the reverse & overdrive clutch (A).

Fig 39: Identifying Reverse & Overdrive Clutch
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust bearing (45798-39060).

Fig 40: Identifying Thrust Bearing (45798-39060)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the overdrive hub (A).

Fig 41: Identifying Overdrive Hub
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust bearing (45798-39060).

Fig 42: Identifying Thrust Bearing (45798-39060)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the reverse sun gear (A).

Fig 43: Identifying Reverse Sun Gear
Courtesy of KIA MOTORS AMERICA, INC.
Remove the piston mounting snap ring (A).

Fig 44: Identifying Piston Mounting Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the 2ND brake piston (A).

Fig 45: Identifying 2ND Brake Piston
Courtesy of KIA MOTORS AMERICA, INC.
Remove the 2ND brake return spring (A).

Fig 46: Identifying 2ND Brake Return Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the 2ND brake pressure plate (A), the brake discs (B), the brake plates (C), the brake reaction plate (D) and the snap ring (E).

Fig 47: Identifying 2ND Brake Discs
Courtesy of KIA MOTORS AMERICA, INC.

Fig 48: Identifying 2ND Brake Pressure Plate, Brake Discs, Brake Plates And Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the Low & reverse planetary gear set (A).

Fig 49: Identifying Low & Reverse Planetary Gear Set
Courtesy of KIA MOTORS AMERICA, INC.
Remove the inner race mounting snap ring (A).

Fig 50: Identifying Inner Race Mounting Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the one way clutch inner race (A).

Fig 51: Identifying One Way Clutch Inner Race
Courtesy of KIA MOTORS AMERICA, INC.
Remove the snap ring (A).

Fig 52: Identifying Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the low & reverse brake discs (A), plates (B) and pressure plate (C).

Fig 53: Identifying Low & Reverse Brake Discs
Courtesy of KIA MOTORS AMERICA, INC.

Fig 54: Identifying Low & Reverse Brake Discs, Plates And Pressure Plate
Courtesy of KIA MOTORS AMERICA, INC.
Remove the wave spring (A).

Fig 55: Identifying Wave Spring
Courtesy of KIA MOTORS AMERICA, INC.
Using the special tool (09493-2F400), remove the snap ring (A).

Fig 56: Identifying Special Tool (09493-2F400) And Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the low & reverse brake spring retainer (A).

Fig 57: Identifying Low & Reverse Brake Spring Retainer
Courtesy of KIA MOTORS AMERICA, INC.
Remove the return spring (A).

Fig 58: Identifying Return Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the low & reverse brake piston (A).

Fig 59: Identifying Low & Reverse Brake Piston
Courtesy of KIA MOTORS AMERICA, INC.
Remove the transfer drive gear (A) ( Screw:8 EA).

Fig 60: Identifying Transfer Drive Gear
Courtesy of KIA MOTORS AMERICA, INC.
Using the special tool (09453-2F100), remove the outer race and spacer of differential bearing from converter housing.
Using the special tool (09453-2F100), remove the outer race of differential bearing from converter housing.