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Repair Procedures: Disassembly

  1. Disconnect the M-terminal on the magnet switch assembly.
  2. After loosening the 3 screws (A), detach the magnet switch assembly (B).
    Fig 1: Identifying Magnet Switch Assembly And Screws
    G06407948Courtesy of KIA MOTORS AMERICA, INC.
  3. Loosen the through bolts (A).
    Fig 2: Identifying Through Bolts
    G06407949Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the brush holder assembly (A), yoke (B) and armature (C).
    Fig 3: Identifying Brush Holder Assembly, Yoke And Armature
    G06407950Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the shield (A) and packing (B).
    Fig 4: Identifying Shield And Packing
    G06407951Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the lever plate (A) and lever packing (B).
    Fig 5: Identifying Lever Plate And Lever Packing
    G06407952Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the planet gear (A).
    Fig 6: Identifying Planet Gear
    G06407953Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the planet shaft assembly (A) and lever (B).
    Fig 7: Identifying Planet Shaft Assembly And Lever
    G06407954Courtesy of KIA MOTORS AMERICA, INC.
  9. Press the stop ring (A) using a socket (B).
    Fig 8: Pressing Stop Ring Using Socket
    G06407955Courtesy of KIA MOTORS AMERICA, INC.
  10. After removing the stopper (A) using stopper pliers (B).
    Fig 9: Removing Stopper Using Stopper Pliers
    G06407956Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the stop ring (A), overrunning clutch (B), internal gear (C) and planet shaft (D).
    Fig 10: Identifying Stop Ring, Overrunning Clutch, Internal Gear And Planet Shaft
    G06407957Courtesy of KIA MOTORS AMERICA, INC.
  12. Reassembly is the reverse of disassembly.
    NOTE: Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).
    Fig 11: Pulling Overrunning Clutch Stop Ring Over Stopper Using Suitable Pulling Tool
    G06407958Courtesy of KIA MOTORS AMERICA, INC.


  1. Disconnect the M-terminal on the magnet switch assembly.
  2. After loosening the 3 screws (A), detach the magnet switch assembly (B).
    Fig 1: Identifying Magnet Switch Assembly And Screws
    G06407959Courtesy of KIA MOTORS AMERICA, INC.
  3. Loosen the through bolts (A).
    Fig 2: Identifying Through Bolts
    G06407960Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the brush holder assembly (A), yoke (B) and armature (C).
    Fig 3: Identifying Brush Holder Assembly, Yoke And Armature
    G06407961Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the shield (A) and packing (B).
    Fig 4: Identifying Shield And Packing
    G06407962Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the lever plate (A) and lever packing (B).
    Fig 5: Identifying Lever Plate And Lever Packing
    G06407963Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the planet gear (A).
    Fig 6: Identifying Planet Gear
    G06407964Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the planet shaft assembly (A) and lever (B).
    Fig 7: Identifying Planet Shaft Assembly And Lever
    G06407965Courtesy of KIA MOTORS AMERICA, INC.
  9. Press the stop ring (A) using a socket (B).
    Fig 8: Pressing Stop Ring Using Socket
    G06407966Courtesy of KIA MOTORS AMERICA, INC.
  10. After removing the stopper (A) using stopper pliers (B).
    Fig 9: Removing Stopper Using Stopper Pliers
    G06407967Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the stop ring (A), overrunning clutch (B), internal gear (C) and planet shaft (D).
    Fig 10: Identifying Stop Ring, Overrunning Clutch, Internal Gear And Planet Shaft
    G06407968Courtesy of KIA MOTORS AMERICA, INC.
  12. Reassembly is the reverse of disassembly.
    NOTE: Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).
    Fig 11: Pulling Overrunning Clutch Stop Ring Over Stopper Using Suitable Pulling Tool
    G06407969Courtesy of KIA MOTORS AMERICA, INC.
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