Automatic Transaxle: Reassembly

CAUTION:

Keep the workbench and parts always clean and dirt free.
Do not use cotton gloves. Use paper towel and nylon rag. Do not use nappy fabric.
Do not use grease at any place otherwise specified. Use white Vaseline or blue mineral oil if necessary.
Insert each snap ring firmly into the seat. Do not use deformed rings.
Do not allow dirt to remain on the surface to apply liquid gasket during reassembly.
Oil pump gasket, valve body mounting bolts (6X25) and oil seals shall not be used again, and use the new ones in assembly.
New clutch and brake discs shall be dipped in ATF for 2 hours or more before use.
In reassembly, replace ATF and cleanse its filter thoroughly. Replace the damaged filter element with a new one.
Apply required minimum quantity of white Vaseline, blue mineral oil, or ATF on each of the bearing part, the thrust face moving part, the oil pump moving part, the seal ring, and the O-ring.
Do not replace the ATF in the fluid cooler.
Be careful not to allow dirt to come through the transaxle openings before transaxle mounting onto the vehicle. (including electronic part connector).

Using SST (09493-2F300), install the differential oil seal on the transaxle case (B).

Fig 1: Identifying SST (09493-2F300)
Courtesy of KIA MOTORS AMERICA, INC.
After applying grease, install the transfer drive gear (A) (8 screws).
TORQUE: 8-12 N.m (80-120Kgf.cm, 6-8 lb-ft)

Fig 2: Identifying Transfer Drive Gear
Courtesy of KIA MOTORS AMERICA, INC.
Install the Low & reverse brake piston (A).
CAUTION: When installing, make sure that the finger of Low and reverse brake piston is seated correctly in groove on the transaxle case.

Fig 3: Identifying Low & Reverse Brake Piston
Courtesy of KIA MOTORS AMERICA, INC.
Install the return spring (A).

Fig 4: Identifying Return Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the Low & reverse brake spring retainer (A).

Fig 5: Identifying Low & Reverse Brake Spring Retainer
Courtesy of KIA MOTORS AMERICA, INC.
Using the special tool (09493-2F400), install the snap ring (A).

Fig 6: Identifying Special Tool (09493-2F400) And Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Install the wave spring (A).

Fig 7: Identifying Wave Spring
Courtesy of KIA MOTORS AMERICA, INC.
In order to measure the Low & reverse brake end play, install the Low & reverse brake plates (5), discs (6), special service tool, reaction plate (1) and snap ring with the special service tool (0.079 in (2 mm)) instead of the selected plate.

Fig 8: [Identifying Reaction Plate And Snap Ring]
Courtesy of KIA MOTORS AMERICA, INC.

Applying 49N (5 Kgf,11 lbf) weight and 245.17 kPa (2.5 Bar, 35.56 psi) air pressure on the plates and discs, measure the end play. At that time, measure the actual gap when releasing the clutch.

Standard value: 0.045-0.057 in (1.15 -1.45 mm)

Fig 9: Measuring End Play

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Choose the proper plate as followed.
For keeping accuracy, measure at least 3 places and calculate the average value.
Pressure plate = [A (travel) + special service tool (0.079 in (2.0 mm)) - Standard value (0.070 in (1.8 mm))]

PRESSURE PLATE REFERENCE

Identification symbol	Thickness in (mm)
45635-23170	0.067 (1.7)
45635-23190	0.075 (1.9)
45635-23210	0.083 (2.1)
45635-23230	0.091 (2.3)
45635-23250	0.098 (2.5)
45635-23270	0.106 (2.7)
45635-23290	0.114 (2.9)

Select the proper plate. After disassembling the snap ring, reassemble the selected plate (C) instead of the special service tool (0.079 in (2.0 mm)), snap ring, low & reverse brake discs (A) and plates (B) and then install the snap ring.

Fig 10: Identifying Low & Reverse Brake Discs
Courtesy of KIA MOTORS AMERICA, INC.

Fig 11: Identifying Low & Reverse Brake Discs And Plates
Courtesy of KIA MOTORS AMERICA, INC.
In order to measure the 2ND brake end play, install the special service tool (0.079 in (2.0 mm)) instead of the selected plate.
1. Install the 2ND brake plate (3), disc (4) and the special service tool (0.079 in (2.0 mm).
2. Install the 2ND brake return spring (A).
  CAUTION: Make sure that the flat face of the return spring should be located to the downward.
  
  Fig 12: Identifying 2ND Brake Return Spring
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the 2ND brake piston (A).
  
  Fig 13: Identifying 2ND Brake Piston
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the piston fixing snap ring (A).
  
  Fig 14: Identifying Piston Mounting Snap Ring
  Courtesy of KIA MOTORS AMERICA, INC.

Applying 49N (5 Kgf,11 lbf) weight and 245.17 kPa (2.5 Bar, 35.56 psi) air pressure on the plates and discs, measure the end play. At that time, measure the actual gap when releasing the clutch.

Standard value: 0.03-0.045 in (0.85-1.15 mm)

Fig 15: Measuring End Play

Courtesy of KIA MOTORS AMERICA, INC.

PRESSURE PLATE REFERENCE

Identification symbol	Thickness in. (mm)
45668-23200	0.079 (2.0)
45668-23220	0.087 (2.2)
45668-23240	0.094 (2.4)
45668-23260	0.106 (2.6)
45635-23280	0.110 (2.8)

After selecting the proper plate, disassemble the snap ring, piston, return spring, disc and plate.
Install the one way clutch inner race (A).

Fig 16: Identifying One Way Clutch Inner Race
Courtesy of KIA MOTORS AMERICA, INC.
Install the inner race fixing snap (A).

Fig 17: Identifying Inner Race Mounting Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Install the Low & reverse planetary gear set (A).

Fig 18: Identifying Low & Reverse Planetary Gear Set
Courtesy of KIA MOTORS AMERICA, INC.
Install the snap ring (E), 2ND brake, pressure plate (A), return spring, plates (C-3EA), discs (B-4EA), reaction plate (D), return spring and 2ND brake piston.

Fig 19: Identifying 2ND Brake Discs
Courtesy of KIA MOTORS AMERICA, INC.

Fig 20: Identifying 2ND Brake Snap Ring, Pressure Plate, Return Spring, Plates And Discs Reaction Plate
Courtesy of KIA MOTORS AMERICA, INC.
Install the snap ring (A).

Fig 21: Identifying Piston Mounting Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Install the reverse sun gear (A).

Fig 22: Identifying Reverse Sun Gear
Courtesy of KIA MOTORS AMERICA, INC.
After applying the grease, install the thrust bearing (45798-39060).
CAUTION: Be careful not to reverse the direction of the thrust bearing.

Fig 23: Identifying Thrust Bearing (45798-39060)
Courtesy of KIA MOTORS AMERICA, INC.
Install the overdrive hub (A).

Fig 24: Identifying Overdrive Hub
Courtesy of KIA MOTORS AMERICA, INC.
After applying the grease, install the thrust bearing (45798-39060).
CAUTION: Be careful not to reverse the direction of the thrust bearing.

Fig 25: Identifying Thrust Bearing (45798-39060)
Courtesy of KIA MOTORS AMERICA, INC.
Install the reverse & overdrive clutch (A).

Fig 26: Identifying Reverse & Overdrive Clutch
Courtesy of KIA MOTORS AMERICA, INC.
After applying the grease, install the thrust bearing (45851-23000).
CAUTION: Be careful not to reverse the direction of the thrust bearing.

Fig 27: Identifying Thrust Bearing (45851-23000)
Courtesy of KIA MOTORS AMERICA, INC.
In order to select the thrust race, install the used thrust bearing. Applying 30N (3Kgf, lb) (A) weight, measure the distance between the rear cover contacting surface of transaxle case and the thrust bearing.
NOTE: Put the flat board or something on the transaxle case to keep accuracy when measuring.
For keeping accuracy, measure at least 3 places and calculate the average value.

Fig 28: Measuring Distance Between Rear Cover Contacting Surface Of Transaxle Case And Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Measure the distance between the contacting surface of the rear cover and the seating surface of thrust race.

Fig 29: Measuring Distance Between Contacting Surface Of Rear Cover And Seating Surface Of Thrust Race
Courtesy of KIA MOTORS AMERICA, INC.

Choose the proper plate as followed.

Thrust race (in (mm)) = [ (A-B)] - end play (0.0098-0.0177 in (0.25-0.45 mm))].

THRUST RACE REFERENCE

Identification symbol	Thickness in (mm)
45853-23013	0.051 (1.3)
45853-23014	0.055 (1.4)
45853-230015	0.059 (1.5)
45853-23016	0.063 (1.6)
45853-23017	0.067 (1.7)
45853-23018	0.071 (1.8)
45853-23019	0.075 (1.9)
45853-23020	0.079 (2.0)
45853-23021	0.083 (2.1)

Install the four seal rings on the rear cover (A).

Fig 30: Identifying Seal Rings On Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the thrust race (A) on the rear cover.

Fig 31: Identifying Thrust Race
Courtesy of KIA MOTORS AMERICA, INC.
Install the five O-rings on the transmission case.

Fig 32: Identifying O-Rings
Courtesy of KIA MOTORS AMERICA, INC.
Apply liquid gasket with 0.063 in (1.6 mm) thickness on the rear cover surface without a pause.
Liquid gasket: Threebond 1281B

Fig 33: Identifying Liquid Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Install the rear cover (9 bolts).
TORQUE: 20-27 N.m (200-270 kgf.cm, 14-19 lb-ft)

Fig 34: Identifying Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.
Insert the four gaskets into feed tube (A) and then install it to the transaxle case.
TORQUE: 28-34 N.m (280-340 kgf.cm, 19-24 lb-ft)

Fig 35: Identifying Feed Tube
Courtesy of KIA MOTORS AMERICA, INC.
Install the manual control shaft (A, including the two O-ring), the detent lever (B) and the parking rod (C).

Fig 36: Identifying Manual Control Shaft, Detent Lever And Parking Rod
Courtesy of KIA MOTORS AMERICA, INC.
Install the reamer bolt on detent lever.
TORQUE: 8-10 N.m (80-100 kgf.cm, 6-7 lb-ft)
Install the manual control shaft fixing groove bolt.
TORQUE: 8-10 N.m (80-100 kgf.cm, 6-7 lb-ft)

Fig 37: Identifying Manual Shaft Mounting Groove Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the detent spring (A).
TORQUE: 8-10 N.m (80-100 kgf.cm, 6-7 lb-ft)

Fig 38: Identifying Detent Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the plate (A) and then tighten the reamer bolt.
TORQUE: 8-10 N.m (80-100 kgf.cm, 6-7 lb-ft)

Fig 39: Identifying Plate
Courtesy of KIA MOTORS AMERICA, INC.
When installing the driven gear, measure the length (A) between both sides of the driven gear with outer races. Measure the length (A) between both sides of the differential gear with outer races. Calculate the sum of the case length and the housing length.
Specified clearance of driven gear: A-C=- 0.0003-0.0035 in (-0.01-0.09 mm)

Specified clearance of differential gear: A-C=-0.0017-0.0041in (-0.045-0.105 mm)
If the calculated value is not within the specified clearance, install the suitable spacer.
Install the driven gear and the outer race.
Install the driven gear (A), the shaft (B) and the sprag spring (C).

Fig 40: Identifying Parking Sprag, Shaft And Sprag Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the inhibitor switch (A) and the manual control lever (B).
TORQUE (shaft nut): 17-21 N.m (170-210 kgf.cm, 13-15 lb-ft)

TORQUE (2bolts): 10-12 N.m (100-120 kgf.cm, 7-8 lb-ft)

Fig 41: Identifying Inhibitor Switch And Manual Control Lever
Courtesy of KIA MOTORS AMERICA, INC.
Install the parking rod guide (A) and oil plate (B) (Bolt:2EA).
TORQUE: 8-10 N.m (80-100 kgf.cm, 6-7 lb-ft)

Fig 42: Identifying Parking Rod Guide And Oil Plate
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil guide plate (B).
TORQUE: 8-10 N.m (80-100 kgf.cm, 6-7 lb-ft)

Fig 43: Identifying Oil Guide Plate
Courtesy of KIA MOTORS AMERICA, INC.
Install the underdrive clutch hub (A).

Fig 44: Identifying Underdrive Clutch Hub
Courtesy of KIA MOTORS AMERICA, INC.
Install the thrust bearing (A).

Fig 45: Identifying Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Be careful not to reverse the direction of the thrust bearing.
Install the underdrive clutch (A).
NOTE: Check that the underdrive clutch is seated correctly.

Fig 46: Identifying Underdrive Clutch
Courtesy of KIA MOTORS AMERICA, INC.
Install the used thrust washer (A).

Fig 47: Identifying Thrust Washer
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump gasket (A).

Fig 48: Identifying Oil Pump Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Using the guide pin (09493-2F600), install the oil pump (A) (Bolt:7 EA).

Fig 49: Identifying Oil Pump
Courtesy of KIA MOTORS AMERICA, INC.
Measure the end play of input shaft and install the spacer if necessary.
Standard value: 0.024-0.043 in (0.6-1.1 mm)

Fig 50: Measuring Input Shaft End Play
Courtesy of KIA MOTORS AMERICA, INC.
Install the two new O-rings.

Fig 51: Locating O-Rings
Courtesy of KIA MOTORS AMERICA, INC.
Install the differential outer race (A).

Fig 52: Identifying Differential Outer Race
Courtesy of KIA MOTORS AMERICA, INC.
Install the differential gear assembly (A).

Fig 53: Identifying Differential Gear Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Using special service tool (09493-2F300), install the oil seal on the torque converter housing.

Fig 54: Identifying Special Service Tool (09493-2F300)
Courtesy of KIA MOTORS AMERICA, INC.
Install the two dowels pin on the torque converter housing.

Fig 55: Locating Dowels Pin On Torque Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil separate (A) (Bolt:3EA).
TORQUE: 8-10 N.m (80-100 kgf.cm, 6-7 lb-ft)

Fig 56: Identifying Oil Separator
Courtesy of KIA MOTORS AMERICA, INC.
Install the spacer (A) on the differential and the transfer driven gear of the torque converter housing.

Fig 57: Identifying Spacer On Differential
Courtesy of KIA MOTORS AMERICA, INC.
Install the driven gear race (A) and the driven gear outer race (B) of the torque converter housing.

Fig 58: Identifying Driven Gear And Driven Gear Race Of Torque Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Apply liquid gasket with 0.063in (1.6mm) thickness on the torque converter housing without a pause.
Liquid gasket: Threebond 1281B

Fig 59: Identifying Liquid Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Install the torque converter housing and tighten the bolt (Bolt: 17EA).
TORQUE: 43-55 N.m (430-550 kgf.cm, 32-41 lb-ft)

Fig 60: Identifying Torque Converter Housing Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the input shaft speed sensor (A) (Bolt:1 EA).
TORQUE: 10-12 N.m (100-120 kgf.cm, 7-8 lb-ft)

Fig 61: Identifying Input Shaft Speed Senor
Courtesy of KIA MOTORS AMERICA, INC.
Install the output shaft speed sensor (A) (Bolt:1 EA).
TORQUE: 10-12 N.m (100-120 kgf.cm, 7-8 lb-ft)

Fig 62: Identifying Output Shaft Speed Senor
Courtesy of KIA MOTORS AMERICA, INC.
Install the plug (A).

Fig 63: Identifying Plug
Courtesy of KIA MOTORS AMERICA, INC.
Install the shift cable bracket (A) (Bolt:2EA).
TORQUE: 19-23 N.m (190-230 kgf.cm, 14-17 lb-ft)

Fig 64: Identifying Shift Cable Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil level gauge (A) and bracket (Bolt:2EA).
TORQUE: 19-23 N.m (190-230 kgf.cm, 14-17 lb-ft)

Fig 65: Identifying Oil Level Gauge With Bracket Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the control valve connector (A).

Fig 66: Identifying Control Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.

Insert each accumulator piston, new sealing and spring.

Fig 67: Identifying Accumulator Piston, Seal Ring And Springs

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Accumulator spring identification.

ACCUMULATOR SPRING IDENTIFICATION

NO.	Use	I.D. Color	Number
A	U/D clutch	White/ White	2
B	O/D clutch	Yellow	1
C	2ND brake	Yellow/Yellow	2
D	L/R brake	Yellow	1

Install the two new O-rings.
NOTE: Insert the new O-ring into the hole of the L/R brake and transfer driven gear.

Fig 68: Locating O-Rings
Courtesy of KIA MOTORS AMERICA, INC.
Install 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 69: Identifying Valve Body Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the manual valve mounting bracket (Nut:1 EA)
TORQUE: 9-12 N.m (90-120 kgf.cm, 6.5-8 lb-ft)

Fig 70: Identifying Manual Valve Mounting Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil filter (A) (Bolt:3EA).
TORQUE: 5-7 N.m (50-70 kgf.cm, 4-5 lb-ft)

Fig 71: Identifying Oil Filter With Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the three magnets in the lower end of the oil filter.

Fig 72: Locating Magnets In Lower End Of Oil Filter
Courtesy of KIA MOTORS AMERICA, INC.
Apply liquid gasket with 0.102 in (2.6 mm) thickness without a pause. See Fig 73.

Fig 73: Identifying Liquid Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Connect the oil pan (A) and tighten the bolt.
TORQUE: 10-12 N.m (100-120 kgf.cm, 7-8 lb-ft)

Fig 74: Identifying Oil Pan With Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the drain plug (A).
TORQUE: 35-45 N.m (350-450 kgf.cm, 25-32 lb-ft)

Fig 75: Identifying Drain Plug
Courtesy of KIA MOTORS AMERICA, INC.