Repair procedures: 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 (09431-39000), install the driveshaft oil seal on the transaxle case (B).

Fig 1: Installing Driveshaft Oil Seal On Transaxle Case
Courtesy of KIA MOTORS AMERICA, INC.
Apply ATF on the torque converter housing (A) and install 2 guide (dowel) pins (B).

Fig 2: Identifying ATF On Torque Converter Housing And Guide Pins
Courtesy of KIA MOTORS AMERICA, INC.
Install the transfer drive gear (A). Tighten the transfer drive gear mounting bolts (8EA) with the specified torque below.
TORQUE:

31.4~ 36.3 Nm (320~370 Kgf.cm, 23.1~26.8 lb-ft)

NOTE: Turn the transfer drive gear one revolution and ensure no interference with bolts.

Fig 3: Tightening Transfer Drive Gear Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the two seal rings (B) and needle roller bearing (A).
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.

Fig 4: Identifying Seal Rings And Needle Roller Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Install the one way clutch (B) and hold it with a snap ring (A).
NOTE: Be cautious to the direction of the one way clutch. Line marked side (C) shall be located forward. (see Fig 6).

Fig 5: Identifying One Way Clutch
Courtesy of KIA MOTORS AMERICA, INC.

Fig 6: Identifying Line Marked Side On One Way Clutch
Courtesy of KIA MOTORS AMERICA, INC.

Fig 7: Tightening Transfer Drive Gear Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
After applying grease, install the low & reverse brake piston (B) and the return spring (A). When installing the piston, align the grooves (C).

Fig 8: Identifying Low & Reverse Brake Piston
Courtesy of KIA MOTORS AMERICA, INC.

Fig 9: Identifying Piston Grooves
Courtesy of KIA MOTORS AMERICA, INC.

Fig 10: Identifying Return Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the spring retainer (B), the one way clutch inner race (A) and a snap ring.

Fig 11: Identifying Spring Retainer
Courtesy of KIA MOTORS AMERICA, INC.

Fig 12: Identifying One Way Clutch Inner Race
Courtesy of KIA MOTORS AMERICA, INC.
Install the wave spring (A).

Fig 13: Identifying Wave Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the brake discs and plates in the sequence below in order to decide the acceptive brake pressure plate satisfying LR brake end play.
[UP] SST (09456-39100) → Disc 2EA → Plate → Disc → Plate → Disc → Plate → Disc → Plate → Disc → Plate [DOWN]
After installing the brake reaction plate, fix the snap ring (thickness:2.3mm) upon it. (It is fine that there is no snap ring under the plate ONLY when measuring.)
Applying 49N (5Kgf,11lbf) weight (A) on the plates and discs and 245.17kPa (2.5 Bar, 35.56psi) pressure (B) through the valve body line, measure the end play with a dial gauge.

Fig 14: Measuring End Play With Dial Gauge
Courtesy of KIA MOTORS AMERICA, INC.

With the formula and the table below, select the adequate low & reverse pressure plate.

Equation: Pressure plate thickness = Travel (A)+SST thickness (1.9mm)-End play

End play: 1.65 ~ 2.11mm (0.0650~0.0831inch)

THICKNESS SPECIFICATIONS

Part No.	Thickness (mm/inch)
45643-39516	1.6/0.0630
45643-39518	1.8/0.0709
45643-39520	2.0/0.0787
45643-39522	2.2/0.0866
45643-39524	2.4/0.0945
45643-39526	2.6/0.1024
45643-39528	2.8/0.1102
45643-39530	3.0/0.1182

After disassembling the SST (09456-39100), snap ring, brake reaction plate and brake plates (5EA)&discs (6EA) again, install the low & reverse pressure plate selected above.
Install the brake plates (5EA)&discs (6EA), snap ring and reaction plate in order below.
[UP] Reaction plate → Snap ring (thickness: 2.0mm) → Disc → Plate → Disc→P late→ Disc→ Plate→ Disc→ Plate→ Disc→ Plate→ Disc [DOWN]

Fig 15: Identifying Brake Plates And Reaction Plate
Courtesy of KIA MOTORS AMERICA, INC.

Afterwards, measuring the gap of reaction plate, select and install the proper snap ring which satisfy the end play condition below.

End play: 0 ~ 0.16mm (0~0.0063inch)

THICKNESS SPECIFICATIONS

Part No.	Thickness (mm/inch)
45665-39500	2.0/0.0787
45665-39522	2.2/0.0866
45665-39523	2.3/0.0906
45665-39524	2.4/0.0945
45665-39525	2.5/0.0984

Disassemble the selected snap ring temporarily.
In order to select the brake pressure plate which satisfy the 2ND brake end play, install the brake discs & plates in order below.
[UP] Disc (Inner disc plate) → Dual side plate (Brake disc) → Two plates (Outer disc plates (no. 2): 2EA) → Disc (Inner disc plate) → Discriminating grooved plate (Outer disc plate (no. 1)) → Disc (Inner disc plate) → SST (09456-39100) [DOWN]
Install the 2ND brake return spring, piston (A) and snap ring.
NOTE: When installing, align the grooves (B) and check up for the 2nd pressure pipe seal (valve body side).

Fig 16: Identifying Piston Grooves
Courtesy of KIA MOTORS AMERICA, INC.
Applying 49N (5Kgf,11lbf) weight (A) on the plates and discs and 245.17kPa (2.5 Bar, 35.56psi) pressure (B) through the valve body line, measure the end play with a dial gauge.

Fig 17: Measuring End Play With Dial Gauge
Courtesy of KIA MOTORS AMERICA, INC.

With the formula and the table below, select the adequate 2nd brake pressure plate.

Equation: Pressure plate thickness = Travel (A)+SST thickness (1.9mm)-End play

End play: 1.09 ~ 1.55mm (0.0429~0.0610inch)

THICKNESS SPECIFICATIONS

Part No.	Thickness (mm/inch)
45643-39243	2.4/0.0945
45643-39263	2.6/0.1024
45643-39283	2.8/0.1102
45643-39303	3.0/0.1181
45643-39323	3.2/0.1260
45643-39343	3.4/0.1339

After disassembling the snap ring, 2ND brake piston, return spring, brake disc set (discs and plates) and SST (09456-39100) again, install the 2ND brake pressure plate selected above.
Install the brake plates & discs, 2nd brake piston, return spring and snap ring in order below.
[UP] Snap ring → 2nd brake piston → Return spring → 2nd brake pressure plate → Dual side plate (Brake disc) → Plate (Outer disc plate (no. 2)) → Disc (Inner disc plate) → Plate (Outer disc plate (no. 2)) → Disc (Inner disc plate) → Discriminating grooved plate (Outer disc plate (no. 1)) → Disc (Inner disc plate) → Selected snap ring → Brake reaction plate [DOWN]

Fig 18: Identifying Brake Plates And Reaction Plate
Courtesy of KIA MOTORS AMERICA, INC.
Install the low & reverse annulus gear assembly (A).

Fig 19: Identifying Low & Reverse Annulus Gear Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install the reverse sun gear assembly (A).

Fig 20: Identifying Reverse Sun Gear Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the overdrive clutch hub (A) and the thrust bearing (B) into the reverse & overdrive clutch. Be careful not to reverse the direction of the thrust bearing.

Fig 21: Identifying Overdrive Clutch Hub And Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Install the thrust bearing (A). Be careful not to reverse the direction of the thrust bearing.

Fig 22: Identifying Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Install the reverse & overdrive clutch assembly (A).

Fig 23: Identifying Reverse & Overdrive Clutch Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install the direct accumulator piston assembly (A) and coil spring (B).

Fig 24: Identifying Direct Accumulator Piston Assembly And Coil Spring
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the thrust bearing (A) and six O-rings (B), Being careful not to reverse the direction of the thrust bearing.

Fig 25: Identifying Thrust Bearing And O-Rings
Courtesy of KIA MOTORS AMERICA, INC.

In order to select the thrust race, install a dial gauge on the rear cover mounting surface and measure the depth (A) to the thrust race contacting surface and the height (B) to the thrust bearing in the reverse & overdrive clutch assembly.

THICKNESS SPECIFICATIONS

Part No.	Thickness (mm/inch)	A-B (mm/inch)
45459-39168	1.6/0.0630	1.9~2.0/0.0748~0.0787
45853-39178	1.7/0.0669	2.0~2.1/0.0787~0.0827
45459-39188	1.8/0.0709	2.1~2.2/0.0827~0.0866
45853-39198	1.9/0.0748	2.2~2.3/0.0866~0.0906
45459-39208	2.0/0.0787	2.3~2.4/0.0906~0.0945
45853-39218	2.1/0.0827	2.4~2.5/0.0945~0.0984
45459-39228	2.2/0.0866	2.5~2.6/0.0984~0.1024
45853-39238	2.3/0.0906	2.6~2.7/0.1024~0.1063
45459-39248	2.4/0.0945	2.7~2.8/0.1063~0.1102
45853-39258	2.5/0.0984	2.8~2.9/0.1102~0.1142
45853-39260	2.8/0.1102	2.9~3.0/0.1142~0.1181

Assemble the thrust race (A) and the four seal rings (B).

Fig 26: Identifying Thrust Race And Seal Rings
Courtesy of KIA MOTORS AMERICA, INC.
Insert the used thrust bearing and install the rear cover (A).
TORQUE:

19.6~ 25.5 Nm (200~260 Kgf.cm, 14.5~18.8 lb-ft)

Fig 27: Identifying Rear Cover Bolts
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Rear cover will be installed in order to check the underdrive sun gear gap.
Measure the underdrive sun gear end play and check if the installed thrust race satisfies the end play condition below.
End play:

0.25 ~ 0.45mm (0.0098~0.0177inch)

Fig 28: Measuring Underdrive Sun Gear End Play
Courtesy of KIA MOTORS AMERICA, INC.
Apply liquid gasket with 1.6mm thickness on the rear cover surface without a pause and tighten the rear cover.
TORQUE:

19.6~ 25.5 Nm (200~260 Kgf.cm, 14.5~18.8 lb-ft)

Liquid gasket: Threebond 1281B or LOCTITE FMD-546

Fig 29: Identifying Liquid Gasket Applying Area To Rear Cover Surface
Courtesy of KIA MOTORS AMERICA, INC.
Insert the anchor plug (B) with a hand matching into the reduction brake band hole (A).

Fig 30: Identifying Anchor Plug And Reduction Brake Band Hole
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the thrust race.
Install the direct clutch (A) with a thrust bearing applied grease.
NOTE: Install the direct clutch (A), turning it counterclockwise.

Fig 31: Identifying Direct Clutch
Courtesy of KIA MOTORS AMERICA, INC.
After tightening the anchor plug with the specified torque below, assemble the reduction brake piston with a snap ring (A) (inner side).
TORQUE:

83.4~112.8Nm (850~1150 Kgf.cm, 61.5~83.2 lb-ft)

Fig 32: Removing Reduction Brake Piston With Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Install the direct planetary carrier assembly (A).
NOTE: Look into the hole where the output speed sensor will be installed, in order to check if the direct planetary carrier assembly is seated correctly.

CAUTION: On moving the transaxle case, be careful that the direct clutch assembly will not slide out.

Fig 33: Identifying Direct Planetary Carrier Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install the parking sprag (A), spring (B) and then the parking sprag shaft.

Fig 34: Identifying Parking Sprag
Courtesy of KIA MOTORS AMERICA, INC.

Fig 35: Identifying Parking Sprag Shaft Spring
Courtesy of KIA MOTORS AMERICA, INC.
Install the parking roller support (A) and the roller shafts (B) (2EA).

Fig 36: Identifying Parking Roller Support
Courtesy of KIA MOTORS AMERICA, INC.

Fig 37: Identifying Roller Shafts
Courtesy of KIA MOTORS AMERICA, INC.
Install the underdrive clutch hub (A).

Fig 38: Identifying Underdrive Clutch Hub
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the thrust bearing (A) and install the underdrive clutch (B) with the input shaft.
CAUTION: Be careful not to reverse the direction of the thrust bearing.

NOTE: Look into the hole where the input speed sensor will be installed, in order to check if the underdrive clutch is seated correctly.

Fig 39: Identifying Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.

Fig 40: Identifying Underdrive Clutch
Courtesy of KIA MOTORS AMERICA, INC.
Install the used thrust washer (A).

Fig 41: Identifying Thrust Washer
Courtesy of KIA MOTORS AMERICA, INC.
Connect the pipe to the oil pump and install the oil pump with a new oil pump gasket.
TORQUE:

9.8~11.8Nm (100~120 Kgf.cm, 7.2~8.7 lb-ft)

CAUTION: Do not reuse the used gasket.
Tighten the oil pump mounting bolt (A) with the TORQUE.
TORQUE:

Tighten the oil pump pipe mounting bolt (B) with the TORQUE.

19.6~25.5Nm (200~260 Kgf.cm, 14.5~18.8 lb-ft)

TORQUE:

9.8~11.8Nm (100~120 Kgf.cm, 7.2~8.7 lb-ft)

Fig 42: Identifying Oil Pump Pipe Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.

Check the input shaft end play and replace the thrust washer which was installed in the step 43 with the appropriate thrust washer from the table below.

End play: 0.70 ~ 1.45mm (0.0276~0.0571inch)

THICKNESS SPECIFICATIONS

Part No.	Thickness (mm/inch)
45544-39180	1.8/0.0709
45544-39200	2.0/0.0787
45544-39220	2.2/0.0866
45544-39240	2.4/0.0945
45544-39260	2.6/0.1024
45544-39280	2.8/0.1102

Fig 43: Checking Input Shaft End Play

Courtesy of KIA MOTORS AMERICA, INC.

Install the two O-rings (A) and the main oil filter (B).

Fig 44: Identifying O-Rings
Courtesy of KIA MOTORS AMERICA, INC.

Fig 45: Identifying Main Oil Filter
Courtesy of KIA MOTORS AMERICA, INC.
Install the differential assembly (A).

Fig 46: Identifying Differential Assembly
Courtesy of KIA MOTORS AMERICA, INC.
With a dial gauge (C), set the torque converter housing mounting surface (B) as its zero point and measure the depth (A) to the differential spacer contacting surface.

Fig 47: Measuring Depth To Differential Spacer Contacting Surface
Courtesy of KIA MOTORS AMERICA, INC.
After installing the differential outer races (A) (2EA-both sides), measure the total differential (B) length (C').

Fig 48: Measuring Total Differential Length
Courtesy of KIA MOTORS AMERICA, INC.
Measure the depth (B) from the transaxle case mounting surface (A) to the differential outer race contacting surface (C).

Fig 49: Measuring Depth From Transaxle Case Mounting Surface To Differential Outer Race Contacting Surface
Courtesy of KIA MOTORS AMERICA, INC.

With the measured data (A', B' and C') in the steps 49~ 51, select the appropriate differential bearing spacer by the equation below.

Equation: Spacer thickness = A'+B'-C' + End play

End play: 0.045 ~ 0.105mm (0.0018~0.0041inch)

THICKNESS SPECIFICATIONS

Part No.	Thickness (mm/inch)	Identification mark
45849-39883	0.83/0.0327	83
45849-39886	0.86/0.0339	86
45849-39889	0.89/0.0350	89
45849-39892	0.92/0.0362	92
45849-39895	0.95/0.0374	95
45849-39898	0.98/0.0386	98
45849-39801	1.01/0.0398	01
45849-39804	1.04/0.0409	04
45849-39807	1.07/0.0421	07
45849-39810	1.10/0.0433	10
45849-39813	1.13/0.0455	13
45849-39816	1.16/0.0457	16
45849-39819	1.19/0.0469	19
45849-39822	1.22/0.0480	22
45849-39825	1.25/0.0492	25
45849-39828	1.28/0.0504	28
45849-39831	1.31/0.0516	31
45849-39834	1.34/0.0528	34
45849-39837	1.37/0.0539	37

Apply liquid gasket at the torque converter housing at ø1.6mm thickness without a pause. See Fig 50.
Liquid gasket: Threebond 1281B or LOCTITE FMD-546

Fig 50: Identifying Liquid Gasket Applying Area To Torque Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Install the torque converter housing (A) and tighten the connecting bolts (B) (20EA) with the TORQUE.
TORQUE:

42~54Nm (428~551 Kgf.cm, 31.0~39.9 lb-ft)

Fig 51: Identifying Torque Converter Housing And Connecting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Applying grease to the O-rings (2EA) of the manual control shaft (B), install the parking roller rod (C), manual control shaft (B) and the shaft (A).

Fig 52: Identifying Parking Roller Rod
Courtesy of KIA MOTORS AMERICA, INC.

Fig 53: Identifying Manual Control Shaft And Parking Roller Rod
Courtesy of KIA MOTORS AMERICA, INC.

Fig 54: Identifying Parking Roller Rod, Manual Control Shaft And Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Install the reduction brake accumulator (D), spring (C), piston (B) and then the snap ring (A).

Fig 55: Identifying Reduction Brake Accumulator, Spring, Piston And Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.

Install each accumulator piston, a new seal ring, and the spring.

NOTE: Accumulator spring identification.

I.D. COLOR REFERENCE CHART

No.	Use	I.D. Color
1	LR brake	Colorless
2	UD clutch	Yellow
3	2ND brake	White
4	OD clutch	Colorless

Install the strainer and the second brake retainer oil seal.
Install the solenoid valve harness and the snap ring around the connector tightly.
Install the valve body (A) and tighten the mounting bolts (28EA).
TORQUE:

9.8~11.8Nm (100~120 Kgf.cm, 7.2~8.7 lb-ft)

Fig 56: Identifying Valve Body
Courtesy of KIA MOTORS AMERICA, INC.
Install the VFS (variable force solenoid) reservoir.
TORQUE:

9.8~11.8Nm (100~120 Kgf.cm, 7.2~8.7 lb-ft)

Unlink the connector harness to the connector and the oil temperature sensor of the valve body.

WIRE COLOR REFERENCE CHART

No.	Connecting point	Wire color	Connector housing color
1	OD solenoid valve	Orange, Red	Black
2	UD solenoid valve	White, Red, Red	Black
3	LR solenoid valve	Brown, yellow	Milky white
4	2nd solenoid valve	Green, Red, Red	Milky white
5	RED solenoid valve	Brown, Yellow, Yellow	Black
6	DCC solenoid valve	Blue, Yellow, Yellow	Black
7	VFS	Brown, Orange	Black
8	Temperature sensor	Black, Red	Black

Install the manual control shaft detent spring (A).
TORQUE:

4.9~6.9 Nm (50~70 Kgf.cm, 3.6~5.1 lb-ft)

Fig 57: Identifying Manual Control Shaft Detent Spring
Courtesy of KIA MOTORS AMERICA, INC.
Apply liquid gasket (A) at the valve body cover (B) at 2.5mm thickness without a pause. See Fig 58.
Liquid gasket: Threebond 1281B or LOCTITE FMD-546

Fig 58: Identifying Liquid Gasket Applying Area To Valve Body Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the valve body cover (A) and tighten the mounting bolts with the TORQUE.
TORQUE:

9.8~11.8Nm (100~120 Kgf.cm, 7.2~8.7 lb-ft)

Fig 59: Identifying Valve Body Cover And Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the vehicle speed sensor (A).
TORQUE:

3.9~5.9Nm (40~60 Kgf.cm, 2.9~4.3 lb-ft)

Fig 60: Identifying Vehicle Speed Sensor
Courtesy of KIA MOTORS AMERICA, INC.
Install the inhibitor switch (A) and the manual control lever (B).
TORQUE:

9.8~11.8Nm (100~120 Kgf.cm, 7.2~8.7 lb-ft) - A

17.7~24.5Nm (180~250 Kgf.cm, 13.0~18.1 lb-ft) - B

CAUTION: The inhibitor switch should be installed with the valve body installed as it was.

Fig 61: Identifying Inhibitor Switch And Manual Control Lever
Courtesy of KIA MOTORS AMERICA, INC.
Install the input (A) and the output speed sensors (B).
TORQUE:

9.8~11.8Nm (100~120 Kgf.cm, 7.2~8.7 lb-ft)

Fig 62: Identifying Input And Output Speed Sensors
Courtesy of KIA MOTORS AMERICA, INC.
Install the eyebolt, a new gasket and the oil cooler feed tube.
Install the oil level gauge.
Install each bracket.
Adjust the reduction brake band by the reduction brake piston which was installed in the step 37.
1. Fix the reduction brake piston not to rotate. Using the SST (09454-3A110), tighten/release the adjusting rod with the specified torque (9.8Nm (100Kgf.cm, 7.2lb-ft)) twice.
  
  Fig 63: Tightening Reduction Brake Piston Using SST (09454-3A110)
  Courtesy of KIA MOTORS AMERICA, INC.
2. Tighten it with the specified torque (4.9Nm (50Kgf.cm, 3.6lb-ft)) and turn it to loose until its 5.5~5.75 revolution.
3. Tighten the reduction brake piston rod fixing nut with the specified torque.
  TORQUE:
  
  14.7~24.5Nm (150~250 Kgf.cm, 10.8~18.1 lb-ft)
Insert the outer reduction brake piston (B) and the snap ring (A).

Fig 64: Identifying Outer Reduction Brake Piston And Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.