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Home >> Kia >> 2009 >> Borrego Limited, 4WD >> Repair and Diagnosis >> Transmission >> Transfer Case Assembly >> Transfer Assembly >> Repair Procedures >> Disassembly

Repair Procedures: Disassembly

  1. Disconnecting the connectors, remove the wiring assembly (A).
    2. Fig 1: Identifying Wiring Assembly
    G06363961Courtesy of KIA MOTORS AMERICA, INC.
  2. Remove the TCCU and motor assembly (A) by removing bolts (B-3ea).
    3. Fig 2: Identifying TCCU & Motor Assembly With Bolts
    G06363962Courtesy of KIA MOTORS AMERICA, INC.
  3. Remove the dynamic damper (A) by removing bolts (B-4ea).
    4. Fig 3: Identifying Dynamic Damper With Bolts
    G06363963Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the nylock nut (A).
    5. Fig 4: Identifying Nylock Nut
    G06363964Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the rear flange (A) by using a puller.
    6. Fig 5: Removing Rear Flange Using Puller
    G06363965Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the transfer cover bolts (A-17ea).
    Fig 6: Identifying Transfer Cover Bolts
    G06363966Courtesy of KIA MOTORS AMERICA, INC.
  7. Using the special tool (09215-3C000), separate the transfer cover and case in two parts.
    8. Fig 7: Separating Transfer Cover & Case Using Special Tool
    G06363967Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the transfer cover (A).
    CAUTION: Do not shake the transfer cover not to damage on matching surface of case & cover and inner parts.
    Fig 8: Identifying Transfer Cover
    G06363968Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the return spring (A).
    10. Fig 9: Identifying Return Spring
    G06363969Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the shift shaft and cam.
  11. Remove the clutch housing (A).
    12. Fig 10: Identifying Clutch Housing
    G06363970Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the lockup clutch (A) with the lockup fork (B).
    13. Fig 11: Identifying Lockup Clutch & Lockup Fork
    G06363971Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the fork rail (A).
    14. Fig 12: Identifying Fork Rail
    G06363972Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the reduction fork (A).
    15. Fig 13: Identifying Reduction Fork
    G06363973Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the oil pump (B) by removing the magnet (A).
    16. Fig 14: Identifying Oil Pump & Magnet
    G06363974Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the main shaft (A).
    17. Fig 15: Identifying Main Shaft
    G06363975Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the reduction hub (A).
    18. Fig 16: Identifying Reduction Hub
    G06363976Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the snap ring (A).
    19. Fig 17: Identifying Snap Ring
    G06363977Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the front output shaft assembly outward from the case.
    20. Fig 18: Removing Front Output Shaft Assembly Outward From Case
    G06363978Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the snap ring (A) between the carrier (B) and ring gear (C).
    21. Fig 19: Identifying Snap Ring, Carrier, & Ring Gear
    G06363979Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove the ring gear (A).
    22. Fig 20: Identifying Ring Gear
    G06363980Courtesy of KIA MOTORS AMERICA, INC.
  22. Widen two ends of the snap ring (A) and remove the carrier assembly (B).
    23. Fig 21: Identifying Snap Ring & Carrier Assembly
    G06363981Courtesy of KIA MOTORS AMERICA, INC.
  23. Pull each wire from the connector housing.
    24. Fig 22: Pulling Each Wire From Connector Housing
    G06363982Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the clutch coil nuts (A-3ea).
    25. Fig 23: Identifying Clutch Coil Nuts
    G06363983Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the clutch coil (A).
Fig 24: Identifying Clutch Coil
G06363984Courtesy of KIA MOTORS AMERICA, INC.
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