LEMON Manuals: Even more car manuals for everyone
Home >> Kia >> 2010 >> Forte SX, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - A5CF2 >> Automatic Transaxle System >> Automatic Transaxle >> Repair procedures >> Disassembly

Repair procedures: Disassembly

  1. Remove the oil feed tube assembly by removing the bolts (A) with washers and the bracket bolt (B).
    Fig 1: Locating Oil Feed Tube Assembly, Bolts, Washers And Bracket Bolt
    G06800680Courtesy of KIA MOTORS AMERICA, INC.
  2. Remove the bracket bolt and pull out the oil filler tube.
    Fig 2: Identifying Bracket Bolt And Oil Filler Tube
    G06800681Courtesy of KIA MOTORS AMERICA, INC.
  3. Remove the manual control lever by removing the nut.
    Fig 3: Identifying Manual Control Lever And Nut
    G06800682Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the inhibiter switch assembly by removing the bolts (2ea).
    Fig 4: Identifying Inhibiter Switch Assembly And Bolts
    G06800683Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the input speed senor by removing the bolt.
    Fig 5: Identifying Input Speed Senor And Bolt
    G06800684Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the output speed senor by removing the bolt.
    Fig 6: Identifying Output Speed Senor And Bolt
    G06800685Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the oil pan by removing the bolts (19ea) and using the oil pan remover.
    Fig 7: Identifying Oil Pan And Bolts
    G06800686Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the manual lever by removing the nut.
    Fig 8: Identifying Manual Lever And Nut
    G06800687Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the main harness connector.
    Fig 9: Identifying Main Harness Connector
    G06800688Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the oil filter by removing the bolts (3ea).
    Fig 10: Identifying Oil Filter And Bolts
    G06800689Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the valve body by removing the bolts (20ea).
    NOTE: 6x30mm (A): 16EA, 6x35mm (B): 1EA, 6x40mm (C): 1EA, 6X55mm (D):1EA, 6x60mm (E): 1EA
    Fig 11: Identifying Valve Body And Bolts
    G06800690Courtesy of KIA MOTORS AMERICA, INC.
  12. After removing the clip (B), remove the control valve connector (A).
    Fig 12: Locating Clip And Control Valve Connector
    G06800691Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove each accumulator piston and the spring.

    Accumulator spring identification 

    ACCUMULATOR SPRING IDENTIFICATION

    NO. Use I.D. Color Spring number
    A Rev clutch Pink 2
    B 2nd brake Pink/Pink 1
    C OD clutch Pink 2
    D UD clutch Green/Green 1
    Fig 13: Locating Accumulator Piston And Spring
    G06800692Courtesy of KIA MOTORS AMERICA, INC.
  14. After removing the bolts (18ea), remove the torque converter housing from the transmission case.
    Fig 14: Identifying Bolts, Torque Converter Housing And Transmission Case (1 Of 3)
    G06800693Courtesy of KIA MOTORS AMERICA, INC.
    Fig 15: Identifying Bolts, Torque Converter Housing And Transmission Case (2 Of 3)
    G06800694Courtesy of KIA MOTORS AMERICA, INC.
    Fig 16: Identifying Bolts, Torque Converter Housing And Transmission Case (3 Of 3)
    G06800695Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the oil separater by removing the bolts (3ea).
    Fig 17: Identifying Oil Separater And Bolts
    G06800696Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the outer race for diffrential bearing from the torque converter housing.
    Fig 18: Identifying Outer Race Of Diffrential Bearing From Torque Converter Housing
    G06800697Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the oil seal from the torque converter housing.
    Fig 19: Identifying Oil Seal On Torque Converter Housing
    G06800698Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the differential assembly.
    Fig 20: Identifying Differential Assembly
    G06800699Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the oil pump assembly by removing the bolts (7ea).
    Fig 21: Identifying Oil Pump Assembly And Bolts
    G06800700Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the thrust washer.
    Fig 22: Identifying Thrust Washer
    G06800701Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove the underdrive clutch assembly.
    Fig 23: Identifying Underdrive Clutch Assembly
    G06800702Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the thrust bearing.
    Fig 24: Identifying Thrust Bearing
    G06800703Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the underdrive clutch hub.
    Fig 25: Identifying Underdrive Clutch Hub
    G06800704Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the parking rod guide by removing the bolts (2ea).
    Fig 26: Identifying Parking Rod Guide And Bolts
    G06800705Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the detent spring by removing the bolt.
    Fig 27: Identifying Detent Spring And Bolt
    G06800706Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the reamer bolt.
    Fig 28: Identifying Reamer Bolt
    G06800707Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the parking sprag rod assembly.
    Fig 29: Removing Parking Sprag Rod Assembly
    G06800708Courtesy of KIA MOTORS AMERICA, INC.
  28. Remove the manual shaft mounting groove bolt.
    Fig 30: Identifying Manual Shaft Mounting Groove Bolt
    G06800709Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the manual control shaft (A) (including the two O-rings), the detent lever (B).
    Fig 31: Locating Manual Control Shaft And Detent Lever
    G06800710Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the parking sprag (A), shaft (B) and sprag spring (C).
    Fig 32: Locating Parking Sprag, Shaft And Sprag Spring
    G06800711Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the transfer driven gear & Direct Planetang Carrier Assembly.
    Fig 33: Identifying Transfer Driven Gear & Direct Planetang Carrier Assembly
    G06800712Courtesy of KIA MOTORS AMERICA, INC.
  32. Remove the direct clutch retairer assembly and the thrust bearing.
    Fig 34: Identifying Direct Clutch Retairer Assembly And Thrust Bearing
    G06800713Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the thrust race.
    Fig 35: Identifying Thrust Race
    G06800714Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the snap ring.
    Fig 36: Identifying Snap Ring
    G06800715Courtesy of KIA MOTORS AMERICA, INC.
  35. Remove the one way clutch assembly.
    Fig 37: Identifying One Way Clutch Assembly
    G06800716Courtesy of KIA MOTORS AMERICA, INC.
  36. Remove the snap rings (2ea).
    Fig 38: Identifying Snap Rings
    G06800717Courtesy of KIA MOTORS AMERICA, INC.
  37. Remove the brake disk set.
    Fig 39: Identifying Brake Disk Set
    G06800718Courtesy of KIA MOTORS AMERICA, INC.
  38. Remove the snap ring by using the SST (09453-1M100).
    Fig 40: Removing Snap Ring By Using SST (09453-1M100)
    G06800719Courtesy of KIA MOTORS AMERICA, INC.
  39. Remove the seal rings (2ea) from the sleeve.
    Fig 41: Identifying Seal Rings
    G06800720Courtesy of KIA MOTORS AMERICA, INC.
  40. Remove the reduction brake spring retainer.
    Fig 42: Identifying Reduction Brake Spring Retainer
    G06800721Courtesy of KIA MOTORS AMERICA, INC.
  41. Remove the reduction brake return spring.
    Fig 43: Identifying Reduction Brake Return Spring
    G06800722Courtesy of KIA MOTORS AMERICA, INC.
  42. Remove the reduction brake piston.
    Fig 44: Identifying Reduction Brake Piston
    G06800723Courtesy of KIA MOTORS AMERICA, INC.
  43. Remove the retainer ring.
    Fig 45: Identifying Retainer Ring
    G06800724Courtesy of KIA MOTORS AMERICA, INC.
  44. Remove the accumulator cover, spring, and piston.
    Fig 46: Identifying Accumulator Cover, Spring, And Piston
    G06800725Courtesy of KIA MOTORS AMERICA, INC.
  45. Remove the O-ring.
    Fig 47: Identifying O-Ring
    G06800726Courtesy of KIA MOTORS AMERICA, INC.
  46. Remove the rear cover assembly by removing the bolts (11ea).
    Fig 48: Identifying Rear Cover Assembly And Bolts
    G06800727Courtesy of KIA MOTORS AMERICA, INC.
  47. Remove the thrust race from the rear cover assembly.
    Fig 49: Identifying Thrust Race And Rear Cover Assembly
    G06800728Courtesy of KIA MOTORS AMERICA, INC.
  48. Remove the D-rings (4ea) from the rear cover assembly.
    Fig 50: Identifying D-Rings And Rear Cover Assembly
    G06800729Courtesy of KIA MOTORS AMERICA, INC.
  49. Remove the accumulator piston and spring.
    Fig 51: Identifying Accumulator Piston And Spring
    G06800730Courtesy of KIA MOTORS AMERICA, INC.
  50. Remove the O-rings (7ea, 1ea)
    Fig 52: Identifying O-Rings
    G06800731Courtesy of KIA MOTORS AMERICA, INC.
  51. Remove the thrust bearing.
    Fig 53: Identifying Thrust Bearing
    G06800732Courtesy of KIA MOTORS AMERICA, INC.
  52. Remove the reverse & overdrive clutch assembly.
    Fig 54: Identifying Reverse & Overdrive Clutch Assembly
    G06800733Courtesy of KIA MOTORS AMERICA, INC.
  53. Remove the overdrive clutch hub and the thrust bearings (2ea).
    Fig 55: Identifying Overdrive Clutch Hub And Thrust Bearings
    G06800734Courtesy of KIA MOTORS AMERICA, INC.
  54. Remove the reverse sun gear assembly.
    Fig 56: Identifying Reverse Sun Gear Assembly
    G06800735Courtesy of KIA MOTORS AMERICA, INC.
  55. Remove the snap ring.
    Fig 57: Identifying Snap Ring
    G06800736Courtesy of KIA MOTORS AMERICA, INC.
  56. Remove the second brake retainer and piston assembly.
    Fig 58: Identifying Second Brake Retainer And Piston Assembly
    G06800737Courtesy of KIA MOTORS AMERICA, INC.
  57. Remove second brake return spring.
    Fig 59: Identifying Second Brake Return Spring
    G06800738Courtesy of KIA MOTORS AMERICA, INC.
  58. Remove the pressure plate, brake disk set, snap ring and reaction plate.
    Fig 60: Identifying Pressure Plate, Brake Disk Set, Snap Ring And Reaction Plate
    G06800739Courtesy of KIA MOTORS AMERICA, INC.
  59. Remove the overdrive & output planetary gear assembly.
    Fig 61: Identifying Overdrive & Output Planetary Gear Assembly
    G06800740Courtesy of KIA MOTORS AMERICA, INC.
  60. Remove the snap ring.
    Fig 62: Identifying Snap Ring
    G06800741Courtesy of KIA MOTORS AMERICA, INC.
  61. Remove the brake disk set and pressure plate.
    Fig 63: Identifying Brake Disk Set And Pressure Plate
    G06800742Courtesy of KIA MOTORS AMERICA, INC.
  62. Remove the wave spring.
    Fig 64: Identifying Wave Spring
    G06800743Courtesy of KIA MOTORS AMERICA, INC.
  63. Remove the snap ring.
    Fig 65: Identifying Snap Ring
    G06800744Courtesy of KIA MOTORS AMERICA, INC.
  64. Remove the one way clutch inner race.
    Fig 66: Identifying One Way Clutch Inner Race
    G06800745Courtesy of KIA MOTORS AMERICA, INC.
  65. Remove the snap ring by using the SST (09453-1M200).
    Fig 67: Removing Snap Ring By Using SST (09453-1M200)
    G06800746Courtesy of KIA MOTORS AMERICA, INC.
  66. Remove the brake spring retainer.
    Fig 68: Identifying Brake Spring Retainer
    G06800747Courtesy of KIA MOTORS AMERICA, INC.
  67. Remove low & reverse brake return spring.
    Fig 69: Identifying Low & Reverse Brake Return Spring
    G06800748Courtesy of KIA MOTORS AMERICA, INC.
  68. Remove low & reverse brake piston.
    Fig 70: Identifying Low & Reverse Brake Piston
    G06800749Courtesy of KIA MOTORS AMERICA, INC.
  69. Remove the transfer drive gear assembly by removing the bolts (4ea+4ea).
    Fig 71: Identifying Transfer Drive Gear Assembly And Bolts
    G06800750Courtesy of KIA MOTORS AMERICA, INC.
  70. Remove the oil guide plate by removing the bolt.
    Fig 72: Identifying Oil Guide Plate And Bolt
    G06800751Courtesy of KIA MOTORS AMERICA, INC.
  71. Remove the outer race for differential bearing from the transmission case.
    Fig 73: Identifying Outer Race Of Differential Bearing
    G06800752Courtesy of KIA MOTORS AMERICA, INC.
  72. Remove the oil seal from the transmission case.
Fig 74: Identifying Oil Seal On Transmission Case
G06800753Courtesy of KIA MOTORS AMERICA, INC.

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 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).
  1. Install the oil seal to the transmission case by using the SST (09453-1M400).
    NOTE: Check if the oil seal is red.
    lubricate with A/T oil.
    Fig 75: Identifying Oil Seal In Transmission Case
    G06800754Courtesy of KIA MOTORS AMERICA, INC.
  2. Install the outer race for differential bearing to the transmission case by using the SST (09453-1M300).
    Fig 76: Identifying Outer Race Of Differential Bearing
    G06800755Courtesy of KIA MOTORS AMERICA, INC.
  3. Install the oil guide plate by installing the bolt.

    Tightening torque : 

    10~12 Nm (1.0~1.2 kgf.m, 7.2~8.7 lb-ft)

    Fig 77: Identifying Oil Guide Plate And Bolt
    G06800756Courtesy of KIA MOTORS AMERICA, INC.
  4. Install the transfer drive gear assembly by installing the bolts (4ea+4ea).

    Tightening torque : 

    8~12 Nm (0.8~1.2 kgf.m, 5.8~8.7 lb-ft)

    Fig 78: Identifying Transfer Drive Gear Assembly And Bolts
    G06800757Courtesy of KIA MOTORS AMERICA, INC.
  5. Install low & reverse brake piston.
    Fig 79: Identifying Low & Reverse Brake Piston
    G06800758Courtesy of KIA MOTORS AMERICA, INC.
  6. Install low & reverse brake return spring.
    Fig 80: Identifying Low & Reverse Brake Return Spring
    G06800759Courtesy of KIA MOTORS AMERICA, INC.
  7. Install the brake spring retainer.
    Fig 81: Identifying Brake Spring Retainer
    G06800760Courtesy of KIA MOTORS AMERICA, INC.
  8. Install the snap ring by using the SST (09453-1M200).
    Fig 82: Installing Snap Ring By Using SST (09453-1M200)
    G06800761Courtesy of KIA MOTORS AMERICA, INC.
  9. Install the one way clutch inner race.
    Fig 83: Identifying One Way Clutch Inner Race
    G06800762Courtesy of KIA MOTORS AMERICA, INC.
  10. Install the snap ring.
    Fig 84: Identifying Snap Ring
    G06800763Courtesy of KIA MOTORS AMERICA, INC.
  11. Install the wave spring.
    Fig 85: Identifying Wave Spring
    G06800764Courtesy of KIA MOTORS AMERICA, INC.
  12. Install the pressure plate, brake disk set.
    Fig 86: Identifying Pressure Plate, Brake Disk Set
    G06800765Courtesy of KIA MOTORS AMERICA, INC.
  13. Install the snap ring.
    Fig 87: Identifying Snap Ring
    G06800766Courtesy of KIA MOTORS AMERICA, INC.

    End play :  1.65 ~ 1.95 mm

    Thickness of pressure plate = (distance between surface of L/R brake piston and end of snap ring) - (distance between end of pressure plate and end of snap ring) under the load of 50N (5kgf)

    PRESSURE PLATE THICKNESS

    Part number Thickness mm(in)
    45635-23160 1.6 (0.063)
    45635-23180 1.8 (0.071)
    45635-23200 2.0 (0.079)
    45635-23220 2.2 (0.087)
    45635-23240 2.4 (0.094)
    45635-23260 2.6 (0.102)
    45635-23280 2.8 (0.110)
    45635-23300 3.0 (0.118)
  14. Install the orerdrive & output planetary gear assembly.
    Fig 88: Identifying Orerdrive & Output Planetary Gear Assembly
    G06800767Courtesy of KIA MOTORS AMERICA, INC.
  15. Install the reaction plate, snap ring and brake disc set.
    Fig 89: Identifying Reaction Plate, Snap Ring And Brake Disc Set
    G06800768Courtesy of KIA MOTORS AMERICA, INC.

    End play :  1.05 ~ 1.35 mm

    Thickness of pressure plate = (distance between end of snap rings of L/R brake and snap ring of 2nd brake) - (distance between floor of 2nd brake piston and end of snap ring of 2nd brake) - (distance between end of snap ring of L/R brake and floor of pressure plate of 2nd brake) under the load of 50N (5kgf)

    PRESSURE PLATE THICKNESS

    Part number Thickness mm(in)
    45668-23140 1.4 (0.055)
    45668-23160 1.6 (0.063)
    45668-23180 1.8 (0.071)
    45668-23200 2.0 (0.079)
    45668-23220 2.2 (0.087)
    45668-23240 2.4 (0.094)
    45668-23260 2.6 (0.102)
    45668-23280 2.8 (0.110)
  16. Install second brake return spring.
    Fig 90: Identifying Second Brake Return Spring
    G06800769Courtesy of KIA MOTORS AMERICA, INC.
  17. Install the second brake retainer and piston assembly.
    Fig 91: Identifying Second Brake Retainer And Piston Assembly
    G06800770Courtesy of KIA MOTORS AMERICA, INC.
  18. Install the snap ring.
    Fig 92: Identifying Snap Ring
    G06800771Courtesy of KIA MOTORS AMERICA, INC.
  19. Install the reverse sun gear assembly.
    NOTE: Check if the low & reverse annulus gear rotates counter clockwise.
    Fig 93: Identifying Reverse Sun Gear Assembly
    G06800772Courtesy of KIA MOTORS AMERICA, INC.
  20. Install the overdrive clutch hub and the thrust bearings (2ea).
    NOTE: Be sure to place the thrust bearings in right direction as shown in the illustration.
    Fig 94: Identifying Overdrive Clutch Hub And Thrust Bearings
    G06800773Courtesy of KIA MOTORS AMERICA, INC.
  21. Install the reverse & overdrive clutch assembly.
    Fig 95: Identifying Reverse & Overdrive Clutch Assembly
    G06800774Courtesy of KIA MOTORS AMERICA, INC.
  22. Install the thrust bearing.
    Fig 96: Identifying Thrust Bearing
    G06800775Courtesy of KIA MOTORS AMERICA, INC.
  23. Install the O-rings (7ea,1ea).
    Fig 97: Identifying O-Rings
    G06800776Courtesy of KIA MOTORS AMERICA, INC.
  24. Install the accumulator piston and spring.
    Fig 98: Identifying Accumulator Piston And Spring
    G06800777Courtesy of KIA MOTORS AMERICA, INC.
  25. Install the D-rings (4ea) to the rear cover assembly.
    Fig 99: Identifying D-Rings And Rear Cover Assembly
    G06800778Courtesy of KIA MOTORS AMERICA, INC.
  26. Install the thrust race to the rear cover assembly.
    Fig 100: Identifying Thrust Race And Rear Cover Assembly
    G06800779Courtesy of KIA MOTORS AMERICA, INC.

    End play :  0.25L ~ 0.45L mm

    Thickness of thrust race = (distance between surface of rear cover contacting the thrust race and surface of transmission case contacting rear cover) - (distance between end of thrust race and surface of rear cover contacting transmission case) while pressing each component forward.

    THRUST RACE THICKNESS

    Part number Thickness mm(in)
    45853-23013 1.3 (0.051)
    45853-23014 1.4 (0.055)
    45853-23015 1.5 (0.059)
    45853-23016 1.6 (0.063)
    45853-23017 1.7 (0.067)
    45853-23018 1.8 (0.071)
    45853-23019 1.9 (0.075)
    45853-23020 2.0 (0.079)
    45853-23021 2.1 (0.083)
  27. Apply liquid gasket with 1.6mm thickness on the rear cover surface.
    Fig 101: Applying Liquid Gasket With 1.6mm Thickness On Rear Cover Surface
    G06800780Courtesy of KIA MOTORS AMERICA, INC.
  28. Install the rear cover assembly by installing the bolts (11ea).

    Tightening torque : 

    20~27 Nm (2.0~2.7 kgf.m, 14.5~19.5 lb-ft)

    Fig 102: Identifying Rear Cover Assembly And Bolts
    G06800781Courtesy of KIA MOTORS AMERICA, INC.
  29. Install the O-ring.
    Fig 103: Identifying O-Ring
    G06800782Courtesy of KIA MOTORS AMERICA, INC.
  30. Install the accumulator piston, spring, and cover.
    Fig 104: Identifying Accumulator Piston, Spring, And Cover
    G06800783Courtesy of KIA MOTORS AMERICA, INC.
  31. Install the retainer ring.
    Fig 105: Identifying Retainer Ring
    G06800784Courtesy of KIA MOTORS AMERICA, INC.
  32. Install the reduction brake piston.
    Fig 106: Identifying Reduction Brake Piston
    G06800785Courtesy of KIA MOTORS AMERICA, INC.
  33. Install the reduction brake spring.
    Fig 107: Identifying Reduction Brake Spring
    G06800786Courtesy of KIA MOTORS AMERICA, INC.
  34. Install the reduction brake spring retainer.
    Fig 108: Identifying Reduction Brake Spring Retainer
    G06800787Courtesy of KIA MOTORS AMERICA, INC.
  35. Install the seal rings (2ea) to the sleeve.
    Fig 109: Identifying Seal Rings
    G06800788Courtesy of KIA MOTORS AMERICA, INC.
  36. Install the snap ring by using the SST (09453-1M100).
    Fig 110: Installing Snap Ring By Using SST (09453-1M100)
    G06800789Courtesy of KIA MOTORS AMERICA, INC.
  37. Install the brake disk set.
    Fig 111: Identifying Brake Disk Set
    G06800790Courtesy of KIA MOTORS AMERICA, INC.
  38. Install the snap rings (A, B).
    Fig 112: Identifying Snap Rings
    G06800791Courtesy of KIA MOTORS AMERICA, INC.

    End play :  1.05 ~ 1.35 mm

    Thickness of snap ring (A) = (distance between surface of Reduction brake piston and end of snap ring (B)) - (thickness of brake disk set) - (thickness of snap ring (B)) under the load of 50N (5kgf).

    SNAP RING THICKNESS

    Part number Thickness mm(in)
    45689-23816 1.6 (0.063)
    45689-23818 1.8 (0.071)
    45689-23820 2.0 (0.079)
    45689-23822 2.2 (0.087)
    45689-23824 2.4 (0.094)
    45689-23826 2.6 (0.102)
    45689-23828 2.8 (0.110)
  39. Install the one way clutch assembly.
    Fig 113: Identifying One Way Clutch Assembly
    G06800792Courtesy of KIA MOTORS AMERICA, INC.
  40. Install the snap ring.
    Fig 114: Identifying Snap Ring
    G06800793Courtesy of KIA MOTORS AMERICA, INC.
  41. Install the thrust race.
    Fig 115: Identifying Thrust Race
    G06800794Courtesy of KIA MOTORS AMERICA, INC.
  42. Install the thrust bearing and the direct clutch retainer assembly.
    Fig 116: Identifying Thrust Bearing And Direct Clutch Retainer Assembly
    G06800795Courtesy of KIA MOTORS AMERICA, INC.
  43. Install the transfer driver gear & direct planetary carrier assembly.
    Fig 117: Identifying Transfer Driver Gear & Direct Planetary Carrier Assembly
    G06800796Courtesy of KIA MOTORS AMERICA, INC.
  44. Install the parking sprag (A), shaft (B) and sprag spring (C).
    Fig 118: Identifying Parking Sprag, Shaft And Sprag Spring
    G06800797Courtesy of KIA MOTORS AMERICA, INC.
  45. Install the manual control shaft (A) (including the two O-rings), the detent lever (B).
    Fig 119: Locating Manual Control Shaft And Detent Lever
    G06800798Courtesy of KIA MOTORS AMERICA, INC.
  46. Install the manual shaft mounting groove bolt.

    Tightening torque : 

    8~10 Nm (0.8~1.0 kgf.m, 5.8~7.2 lb-ft)

    Fig 120: Identifying Manual Shaft Mounting Groove Bolt
    G06800799Courtesy of KIA MOTORS AMERICA, INC.
  47. Install the parking sprag rod assembly.
    Fig 121: Installing Parking Sprag Rod Assembly
    G06800800Courtesy of KIA MOTORS AMERICA, INC.
  48. Install the reamer bolt.

    Tightening torque : 

    8~10 Nm (0.8~1.0 kgf.m, 5.8~7.2 lb-ft)

    Fig 122: Identifying Reamer Bolt
    G06800801Courtesy of KIA MOTORS AMERICA, INC.
  49. Install the detent spring by installing the bolt.

    Tightening torque : 

    8~10 Nm (0.8~1.0 kgf.m, 5.8~7.2 lb-ft)

    Fig 123: Identifying Detent Spring And Bolt
    G06800802Courtesy of KIA MOTORS AMERICA, INC.
  50. Install the parking rod guide by installing the bolts (2ea).

    Tightening torque : 

    8~10 Nm (0.8~1.0 kgf.m, 5.8~7.2 lb-ft)

    Fig 124: Identifying Parking Rod Guide And Bolts
    G06800803Courtesy of KIA MOTORS AMERICA, INC.
  51. Install the underdrive clutch hub.
    Fig 125: Identifying Underdrive Clutch Hub
    G06800804Courtesy of KIA MOTORS AMERICA, INC.
  52. Install the thrust bearing.
    NOTE: Be sure to place the thrust bearings in right direction as shown in the illustration.
    Fig 126: Identifying Thrust Bearing
    G06800805Courtesy of KIA MOTORS AMERICA, INC.
  53. Install the underdrive clutch assembly.
    Fig 127: Identifying Underdrive Clutch Assembly
    G06800806Courtesy of KIA MOTORS AMERICA, INC.
  54. Install the thrust washer.
    Fig 128: Identifying Thrust Washer
    G06800807Courtesy of KIA MOTORS AMERICA, INC.

    End play :  0.7L ~ 1.25L mm

    Thickness of thrust washer = (distance between surface of OD clutch contacting the thrust washer and surface of transmission case contacting oil pump) - (distance between center end of oil pump and surface of oil pump contacting transmission case) while pressing each component forward.

    THRUST WASHER THICKNESS

    Part number Thickness mm(in)
    45456-23160 1.6 (0.063)
    45544-23180 1.8 (0.071)
    45544-23200 2.0 (0.079)
    45544-23220 2.2 (0.087)
    45544-23240 2.4 (0.094)
    45544-23260 2.6 (0.102)
    45544-23280 2.8 (0.110)
  55. Install the oil pump assembly by installing the bolts (7ea).

    Tightening torque : 

    20~27 Nm (2.0~2.7 kgf.m, 14.5~19.5 lb-ft)

    NOTE: Be sure that the two oil seals and O-ring are on the oil pump assembly.
    Fig 129: Identifying Oil Pump Assembly And Bolts
    G06800808Courtesy of KIA MOTORS AMERICA, INC.
  56. Install the differential assembly.
    Fig 130: Identifying Differential Assembly
    G06800809Courtesy of KIA MOTORS AMERICA, INC.
  57. Install the oil seal to the torque converter housing by using the SST (09453-1M400).
    NOTE: Check if the oil seal is blue.
    lubricate with A/T oil.
    Fig 131: Identifying Oil Seal On Torque Converter Housing By Using SST (09453-1M400)
    G06800810Courtesy of KIA MOTORS AMERICA, INC.
  58. Install the outer race for diffrential bearing to the torque converter housing by using the SST (09453-1M300).
    Fig 132: Identifying Outer Race Of Diffrential Bearing
    G06800811Courtesy of KIA MOTORS AMERICA, INC.
  59. Install the oil separater by installing the bolts (3ea).

    Tightening torque : 

    9~12 Nm (0.9~1.2 kgf.m, 6.5~8.7 lb-ft)

    Fig 133: Identifying Oil Separater And Bolts
    G06800812Courtesy of KIA MOTORS AMERICA, INC.
  60. Apply liquid gasket with 1.6mm thickness on surface of the torque converter housing.
    Fig 134: Applying Liquid Gasket With 1.6mm Thickness On Surface Of Torque Converter Housing
    G06800813Courtesy of KIA MOTORS AMERICA, INC.
  61. After installing the bolts (18ea), Install the torque converter housing to the transmission case.

    Tightening torque : 

    43~55 Nm (4.3~5.5 kgf.m, 31.1~39.8 lb-ft)

    Fig 135: Identifying Torque Converter Housing To Transmission Case Bolts (1 Of 3)
    G06800814Courtesy of KIA MOTORS AMERICA, INC.
    Fig 136: Identifying Torque Converter Housing To Transmission Case Bolts (2 Of 3)
    G06800815Courtesy of KIA MOTORS AMERICA, INC.
    Fig 137: Identifying Torque Converter Housing To Transmission Case Bolts (3 Of 3)
    G06800816Courtesy of KIA MOTORS AMERICA, INC.
  62. Install each spring and accumulator piston.

    Accumulator spring identification 

    ACCUMULATOR SPRING IDENTIFICATION

    NO. Use I.D. Color Spring number
    A Rev clutch Pink 2
    B 2nd brake Pink/Pink 1
    C O/D clutch Pink 2
    D U/D clutch Green/Green 1
    Fig 138: Locating Spring And Accumulator Piston
    G06800817Courtesy of KIA MOTORS AMERICA, INC.
  63. After installing the clip (B), Install the control valve connector (A).
    Fig 139: Locating Clip And Control Valve Connector
    G06800818Courtesy of KIA MOTORS AMERICA, INC.
  64. Install the valve body by installing the bolts (20ea).

    Tightening torque : 

    10~12 Nm (1.0~1.2 kgf.m, 7.2~8.7 lb-ft)

    NOTE: 6x30mm (A): 16EA, 6x35mm (B): 1EA, 6x40mm (C): 1EA, 6X55mm (D):1EA, 6x60mm (E): 1EA
    Fig 140: Identifying Valve Body And Bolts
    G06800819Courtesy of KIA MOTORS AMERICA, INC.
  65. Install the oil filter by installing the bolts (3ea).

    Tightening torque : 

    10~12 Nm (1.0~1.2 kgf.m, 7.2~8.7 lb-ft)

    Fig 141: Identifying Oil Filter And Bolts
    G06800820Courtesy of KIA MOTORS AMERICA, INC.
  66. diskonnect the main harness connector.
    Fig 142: Identifying Main Harness Connector
    G06800821Courtesy of KIA MOTORS AMERICA, INC.
  67. Install the manual lever by installing the nut.

    Tightening torque : 

    9~12 Nm (0.9~1.2 kgf.m, 6.5~8.7 lb-ft)

    Fig 143: Identifying Manual Lever And Nut
    G06800822Courtesy of KIA MOTORS AMERICA, INC.
  68. Apply liquid gasket with 2.5mm thickness on surface of the oil pan.
    Fig 144: Applying Liquid Gasket With 2.5mm Thickness On Surface Of Oil Pan
    G06800823Courtesy of KIA MOTORS AMERICA, INC.
  69. Install the oil pan by installing the bolts (19ea).

    Tightening torque : 

    10~12 Nm (1.0~1.2 kgf.m, 7.2~8.7 lb-ft)

    NOTE: Check if there are the three magnets on the oil pan.
    Fig 145: Identifying Oil Pan And Bolts
    G06800824Courtesy of KIA MOTORS AMERICA, INC.
  70. Install the output speed senor by installing the bolt.

    Tightening torque : 

    6~8 Nm (0.6~0.8 kgf.m, 4.3~5.8 lb-ft)

    Fig 146: Identifying Output Speed Senor And Bolt
    G06800825Courtesy of KIA MOTORS AMERICA, INC.
  71. Install the input speed senor by installing the bolt.

    Tightening torque : 

    6~8 Nm (0.6~0.8 kgf.m, 4.3~5.8 lb-ft)

    Fig 147: Identifying Input Speed Senor And Bolt
    G06800826Courtesy of KIA MOTORS AMERICA, INC.
  72. Install the inhibiter switch assembly by installing the bolts (2ea).

    Tightening torque : 

    10~12 Nm (1.0~1.2 kgf.m, 7.2~8.7 lb-ft)

    Fig 148: Identifying Inhibiter Switch Assembly And Bolts
    G06800827Courtesy of KIA MOTORS AMERICA, INC.
  73. Install the manual control lever by installing the nut with a new washer.
    Fig 149: Identifying Manual Control Lever, Nut And Washer
    G06800828Courtesy of KIA MOTORS AMERICA, INC.
  74. After inserting the oil gauge guide, install the bracket bolt.

    Tightening torque : 

    19~23 Nm (1.9~2.3 kgf.m, 13.7~16.6 lb-ft)

    Fig 150: Identifying Inserting Oil Gauge Guide And Bracket Bolt
    G06800829Courtesy of KIA MOTORS AMERICA, INC.
  75. Install the oil cooler tube assembly by installing the bolts (A) with washers and the bracket bolt (B).

Tightening torque: 

[A] 28~34 Nm (2.8~3.4 kgf.m)

[B] 19~23 Nm (1.9~2.3 kgf.m, 13.7~16.6 lb-ft)

Fig 151: Locating Oil Cooler Tube Assembly, Bolts, Washers And Bracket Bolt
G06800830Courtesy of KIA MOTORS AMERICA, INC.
scientia non olet · About LEMON Manuals