Repair procedures: 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.
Measure the input shaft (A) end play using a dial gauge.
Input shaft end play:

0.7~1.45mm (0.0276~0.0571 inch)

Fig 1: Measuring Input Shaft End Play Using Dial Gauge
Courtesy of KIA MOTORS AMERICA, INC.
Remove the fluid level gauge.
Remove the input (A) and the output speed sensor (B).

Fig 2: Identifying Input And Output Speed Sensor
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Remove the eyebolt, the gasket, and the fluid cooler feed tube.
Remove the manual control lever (B) and the transaxle range switch (A).
CAUTION: Remove the transaxle range switch (A) with the valve body installed.

Fig 3: Identifying Transaxle Range Switch And Manual Control Lever
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Remove the speedometer gear (or vehicle speed sensor (A)).

Fig 4: Identifying Speedometer Gear And Vehicle Speed Sensor
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Using the SST (09215-3C000), remove the valve body cover (A).

Fig 5: Identifying Valve Body Cover
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Remove the manual control shaft detent spring (A).

Fig 6: Identifying Manual Control Shaft Detent Spring
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Remove the VFS (variable force solenoid) reservoir (A) and tube assembly (B).

Fig 7: Identifying VFS Reservoir And Tube Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the harness connector from the valve body.
Remove the valve body mounting bolts (26EA), except those bolts (A) marked on illustration. (6X45-1EA, 6X75-1EA, 6X106-10EA, 6X38-9EA, 6X20-2EA, 6X25-2EA, 6X30-1EA)

Fig 8: Identifying Valve Body Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the valve body (A) and the steel balls (2EA).
CAUTION: Be careful not to lose the steel balls.

Fig 9: Identifying Valve Body
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Remove the solenoid valve harness snap ring (A).

Fig 10: Identifying Solenoid Valve Harness Snap Ring
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Remove the solenoid valve harness.
Remove the strainer (A).

Fig 11: Identifying Strainer
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Remove the 2ND brake retainer oil seal (A).
CAUTION: If the 2ND brake retainer oil seal is not removed, it may be damaged when removing and installing the second brake piston.

Fig 12: Identifying 2ND Brake Retainer Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.

Remove each accumulator piston and spring.

BRAKE PISTON NAME REFERENCE CHART

No.	Name
1	Low & Reverse brake
2	Under drive clutch
3	Second brake
4	Over drive clutch

Fig 13: Identifying Accumulator Piston And Spring

Courtesy of KIA MOTORS AMERICA, INC.

Remove the snap ring (A), the piston (B) and reduction brake accumulator (D) and the spring (C).

Fig 14: Identifying Snap Ring, Piston, Reduction Brake Accumulator And Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the snap ring (A) and the reduction brake piston (B).

Fig 15: Identifying Snap Ring And Reduction Brake Piston
Courtesy of KIA MOTORS AMERICA, INC.
Remove the snap ring (A) inside first. Afterwards, remove the nut (D), the reduction brake piston (B) and the spring (C).

Fig 16: Removing Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.

Fig 17: Identifying Reduction Brake Piston, Spring And Nut
Courtesy of KIA MOTORS AMERICA, INC.
After pulling out the roller pin (A), remove the manual control shaft assembly (B) and the parking roller rod assembly (C).

Fig 18: Identifying Roller Pin, Manual Control Shaft Assembly And Parking Roller Rod Assembly
Courtesy of KIA MOTORS AMERICA, INC.

Fig 19: Identifying Manual Control Shaft Assembly And Parking Roller Rod Assembly
Courtesy of KIA MOTORS AMERICA, INC.

Fig 20: Identifying Parking Roller Rod Assembly
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Loosen the torque converter housing mounting bolts (20EA) and remove the torque converter housing.
Remove the two O-rings (A) (2EA).

Fig 21: Identifying O-Rings
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Remove the differential assembly (A).

Fig 22: Identifying Differential Assembly
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Remove the main oil filter (B).

Fig 23: Identifying Main Oil Filter
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Release the oil pump mounting bolts (A) (6EA) and the oil pump pipe mounting bolts (B) (2EA).
CAUTION: Do not disassemble the oil pump. Misalignment during assembly may damage the pump and the transaxle.

Fig 24: Identifying Oil Pump Pipe Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump and the oil pump gasket.
Separate the oil pump pipe from the oil pump.
Remove the thrust washer (A).

Fig 25: Identifying Thrust Washer
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Hold the input shaft with a hand and remove the underdrive clutch (B).

Fig 26: Identifying Underdrive Clutch
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Remove the thrust bearing (A).

Fig 27: Identifying Thrust Bearing
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Remove the underdrive clutch hub (A).

Fig 28: Identifying Underdrive Clutch Hub
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Remove the parking roller supporting shafts (B) (2EA).

Fig 29: Identifying Parking Roller Supporting Shafts
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Remove the parking roller support (A).

Fig 30: Identifying Parking Roller Support
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Remove the parking sprag shaft (A).

Fig 31: Identifying Parking Sprag Shaft
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Remove the parking sprag spring (B).

Fig 32: Identifying Parking Sprag Spring
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Remove the parking sprag (A).

Fig 33: Identifying Parking Sprag
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Remove the direct planetary carrier assembly (A).

Fig 34: Identifying Direct Planetary Carrier Assembly
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Remove the direct clutch assembly (A).

Fig 35: Identifying Direct Clutch Assembly
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Remove the reduction brake band (A).

Fig 36: Identifying Reduction Brake Band
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Remove the anchor plug (A) and a O-ring.

Fig 37: Identifying Anchor Plug And O-Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust bearing (A) and race.

Fig 38: Identifying Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the rear cover (A).

Fig 39: Identifying Rear Cover
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Remove the thrust race (A) and the seal rings (B) (4EA).

Fig 40: Identifying Thrust Race And Seal Rings
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust bearing (A) and the O-rings (B) (6EA).

Fig 41: Identifying Thrust Bearing And O-Rings
Courtesy of KIA MOTORS AMERICA, INC.
Remove the direct accumulator piston assembly (A) and the coil spring (B).

Fig 42: Identifying Direct Accumulator Piston Assembly And Coil Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the reverse and overdrive clutch (A).

Fig 43: Identifying Reverse And Overdrive Clutch
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Remove the thrust bearing (A).

Fig 44: Identifying Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the overdrive clutch hub (A) and the thrust bearing (B).

Fig 45: Identifying Overdrive Clutch Hub And Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the reverse sun gear (A).

Fig 46: Identifying Reverse Sun Gear
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Remove the planetary gear assembly (A).

Fig 47: Identifying Planetary Gear Assembly
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Remove the second brake snap ring and retainer (A).

Fig 48: Identifying Second Brake Snap Ring And Retainer
Courtesy of KIA MOTORS AMERICA, INC.
Remove the second brake return spring (A).

Fig 49: Identifying Second Brake Return Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the second brake pressure plate (A), brake discs (B) (4EA) and plates (C) (3EA).

Fig 50: Identifying Second Brake Pressure Plate, Brake Discs And Plates
Courtesy of KIA MOTORS AMERICA, INC.
Remove a snap ring.
Remove the brake reaction plate (A) and snap ring (B).

Fig 51: Identifying Brake Reaction Plate
Courtesy of KIA MOTORS AMERICA, INC.

Fig 52: Identifying Snap Ring
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Remove the brake discs (A) (6EA) and plates (B) (5EA).

Fig 53: Identifying Brake Discs And Plates
Courtesy of KIA MOTORS AMERICA, INC.
Remove the LR brake pressure plate (A).

Fig 54: Removing LR Brake Pressure Plate
Courtesy of KIA MOTORS AMERICA, INC.
Remove the wave spring (A).

Fig 55: Identifying Wave Spring
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Remove the snap ring (A) using SST (09453-3A110).

Fig 56: Removing Snap Ring Using SST (09453-3A110)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the one way clutch inner race (A) and brake spring retainer (B).

Fig 57: Identifying One Way Clutch Inner Race
Courtesy of KIA MOTORS AMERICA, INC.

Fig 58: Identifying Brake Spring Retainer
Courtesy of KIA MOTORS AMERICA, INC.
Remove the LR brake return spring (A) and piston (B).

Fig 59: Identifying LR Brake Return Spring
Courtesy of KIA MOTORS AMERICA, INC.

Fig 60: Identifying Piston
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After removing the snap ring (A) fixing the one way clutch, take off the one way clutch (B).

Fig 61: Identifying Snap Ring
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Fig 62: Identifying One Way Clutch
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Remove the seal rings (B) (2EA) and needle roller bearing (A).

Fig 63: Identifying Seal Rings And Needle Roller Bearing
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Do not replace the rear bearing if there's no fault after checking because the transaxle case may be damaged in replacing the rear bearing.
Release the transfer drive gear (A) mounting bolts (8EA).
NOTE: After releasing the four bolts, first, find the others by revolving the gear.

Fig 64: Removing Transfer Drive Gear Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the transfer drive gear (A).

Fig 65: Identifying Transfer Drive Gear
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Remove the differential bearing outer race (B) from the transaxle case (A).

Fig 66: Identifying Differential Bearing Outer Race And Transaxle Case
Courtesy of KIA MOTORS AMERICA, INC.
Remove the differential bearing outer race (B) and spacer from the converter housing (A).

Fig 67: Identifying Differential Bearing Outer Race And Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the differential oil seal (A).

Fig 68: Tapping Differential Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.