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

Repair Procedures: Reassembly

  1. Install the clutch coil (A).
    2. Fig 1: Identifying Clutch Coil
    G06363985Courtesy of KIA MOTORS AMERICA, INC.
  2. Install the clutch coil nuts (A-3ea).
    3. Fig 2: Identifying Clutch Coil Nuts
    G06363986Courtesy of KIA MOTORS AMERICA, INC.
  3. Insert each wire to the connector housing.
    4. Fig 3: Inserting Each Wire To Connector Housing
    G06363987Courtesy of KIA MOTORS AMERICA, INC.
  4. Widen two ends of the snap ring (A) and install the carrier assembly (B).
    5. Fig 4: Identifying Snap Ring & Carrier Assembly
    G06363988Courtesy of KIA MOTORS AMERICA, INC.
  5. Install the ring gear (A).
    6. Fig 5: Identifying Ring Gear
    G06363989Courtesy of KIA MOTORS AMERICA, INC.
  6. Install the snap ring (A) between the carrier (B) and ring gear (C).
    7. Fig 6: Identifying Snap Ring, Carrier, & Ring Gear
    G06363990Courtesy of KIA MOTORS AMERICA, INC.
  7. Install the front output shaft assembly outward from the case.
    8. Fig 7: Installing Front Output Shaft Assembly Outward From Case
    G06363991Courtesy of KIA MOTORS AMERICA, INC.
  8. Install the snap ring (A).
    9. Fig 8: Identifying Snap Ring
    G06363992Courtesy of KIA MOTORS AMERICA, INC.
  9. Install the reduction hub (A).
    10. Fig 9: Identifying Reduction Hub
    G06363993Courtesy of KIA MOTORS AMERICA, INC.
  10. Install the main shaft (A).
    11. Fig 10: Identifying Main Shaft
    G06363994Courtesy of KIA MOTORS AMERICA, INC.
  11. Install the oil filter (B) and the magnet (A).
    12. Fig 11: Identifying Oil Filter & Magnet
    G06363995Courtesy of KIA MOTORS AMERICA, INC.
  12. Install the reduction fork (A).
    13. Fig 12: Identifying Reduction Fork
    G06363996Courtesy of KIA MOTORS AMERICA, INC.
  13. Install the shift shaft and cam.
  14. Install the fork rail (A).
    15. Fig 13: Identifying Fork Rail
    G06363997Courtesy of KIA MOTORS AMERICA, INC.
  15. Install the lockup clutch (A) with the lockup fork (B).
    16. Fig 14: Identifying Lockup Clutch With Lockup Fork
    G06363998Courtesy of KIA MOTORS AMERICA, INC.
  16. Install the clutch housing (A).
    17. Fig 15: Identifying Clutch Housing
    G06363999Courtesy of KIA MOTORS AMERICA, INC.
  17. Install the return spring (A).
    18. Fig 16: Identifying Return Spring
    G06364000Courtesy of KIA MOTORS AMERICA, INC.
  18. Grease the contact surface of the cover and install the transfer cover (A).
    19. Fig 17: Identifying Transfer Cover
    G06364001Courtesy of KIA MOTORS AMERICA, INC.
  19. Install the transfer cover bolts (A-17ea).
    20. Fig 18: Identifying Transfer Cover Bolts
    G06364002Courtesy of KIA MOTORS AMERICA, INC.
  20. Install the rear flange (A) by using press.
    21. Fig 19: Installing Rear Flange Using Press
    G06364003Courtesy of KIA MOTORS AMERICA, INC.
  21. Install the nylock nut (A).
    22. Fig 20: Identifying Nylock Nut
    G06364004Courtesy of KIA MOTORS AMERICA, INC.
  22. Install the dynamic damper (A) by installing bolts (B-4ea).
    23. Fig 21: Identifying Dynamic Damper With Bolts
    G06364005Courtesy of KIA MOTORS AMERICA, INC.
  23. Install the TCCU and motor assembly (A) by installing bolts (B-3ea).
    24. Fig 22: Identifying TCCU & Motor Assembly With Bolts
    G06364006Courtesy of KIA MOTORS AMERICA, INC.
  24. Connecting the connectors, install the wiring assembly (A).
Fig 23: Identifying Wiring Assembly
G06364007Courtesy of KIA MOTORS AMERICA, INC.
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