Automatic Transaxle: Reassembly

Use drift to punch the oil seal (2).

Fig 1: Punching Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Assembly the manual shaft and the manual plate parking road.

Fig 2: Assembling Manual Shaft And Manual Plate Parking Road
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Punch the spring pin that attaches the manual plate to the manual shaft.
Use the punch or something similar to fit with the holes.

Make sure that the spring pin can be pulled out. Leave 2 +/-0.5 mm(0.0787~0.0197in.) of the tip.

Fig 3: Punching Spring Pin
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Use the punch or something similar to locate the hole of the spring pin that attaches the manual shaft to the case.

Fig 4: Locating Hole Of Spring Pin
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Attach the manual shaft to the case. Punch the spring pin. Leave 5 +/-1 mm(0.1969~ 0.0394in.).

Fig 5: Attaching Manual Shaft To Case
Courtesy of KIA MOTORS AMERICA, INC.
Apply vaseline to the terminal assembly installation hole.

Fig 6: Applying Vaseline To Terminal Assembly Installation Hole
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Insert the terminal assembly to the installation hole.

Fig 7: Inserting Terminal Assembly To Installation Hole
Courtesy of KIA MOTORS AMERICA, INC.
Attach the terminal connector to the bracket.
The position for each connector is as in figure below.

Fig 8: Attaching Terminal Connector To Bracket
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Attach the servo piston, servo retainer, and servo stem return spring to the case.

Fig 9: Attaching Servo Piston, Servo Retainer, And Servo Stem Return Spring To Case
Courtesy of KIA MOTORS AMERICA, INC.
Attach the snap ring of the servo.

Fig 10: Attaching Snap Ring Of Servo
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Fix the detent spring.
Tightening torque: 6.9 ~ 8.8 Nm (69 ~ 88kg.cm, 5.1 ~ 6.5lbf.ft)

Fig 11: Fixing Detent Spring
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Apply Vaseline to the outer O-ring of the reverse brake piston.
Assembly the reverse brake piston.
Apply the drum support bearing to install.

Fig 12: Assembling Reverse Brake Piston
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Assembly the return spring of the reverse brake piston and the spring retainer.
Use the clutch compressor to install the snap ring that installs the spring retainer.

Use the driver to make sure since the tension of the snap ring is somewhat weak.

Fig 13: Installing Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Assembly the reverse brake clutches.

Fig 14: Assembling Reverse Brake Clutches
Courtesy of KIA MOTORS AMERICA, INC.

Assembly SPG to prevent shattering.

Fig 15: Assembling SPG To Prevent Shattering

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Adjust the gap between reverse ~ brake Check L dimension using a thickness gauge and adjust it to become 0.7 ~ 1.1 mm(0.0276 ~ 0.0433in.) using the retainer plate. When L dimension is not within the aforesaid values, check the thickness of the retainer plate and select the proper part of the following table and replace it.

PART NUMBER AND DIMENSION REFERENCE

Part number	Dimension [mm(in.)]
45627-4C000	4.2 (0.1654)
45627-4C001	4.4 (0.1732)
45627-4C002	4.6 (0.1811)
45627-4C003	4.8 (0.1890)
45627-4C004	5.0 (0.1969)

Assembly the snap ring that is for fixing the reverse brake plates.

Fig 16: Assembling Snap Ring
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Install the bearing that Vaseline has been applied to the rear case surface.

Fig 17: Installing Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Scratch off the sealant.

Fig 18: Scratching Off Sealant
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Wipe the surface that is in contact with the extension with an oil whetstone lightly and remove the sealant completely.
Tap the seal bolt slit lightly.

Apply the washer fluid to wipe with the whetstone so that the removed gasket not to become sticking.

Fig 19: Identifying Location Seal Bolt Hole
Courtesy of KIA MOTORS AMERICA, INC.
Scratch off the sealant that is attached to the surface that is contact with the case.

Fig 20: Scratching Off Sealant
Courtesy of KIA MOTORS AMERICA, INC.
Wipe the surface conjoined with the case with oil whetstone lightly and remove the sealant completely. Tap the seal bolt slit lightly.
Apply the washer fluid to wipe with the whetstone so that the case not to become sticking after cleaning.

Fig 21: Wiping Surface
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Install the return spring to the parking pole. See the following figure when mounting.

Fig 22: Installing Return Spring
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Install the parking pole, return spring shaft.

Fig 23: Installing Parking Pole, Return Spring Shaft
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Install the actuator support.

Fig 24: Installing Actuator Support
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Assemble the output shat.
CAUTION: Note that the shapes of the front and back are similar. (Front side is where the tip outer diameter is narrower (Torque converter side))

See the shape figure.

Fig 25: Assembling Output Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Install the revolution sensor.
Tightening torque: 4.6 ~ 6.9Nm(46 ~ 69kg.cm, 3.4 ~ 5.1 lbf.ft)

Fig 26: Installing Revolution Sensor
Courtesy of KIA MOTORS AMERICA, INC.
Apply the sealant to the surface in contact with the extension case.
CAUTION: Use Loctite 518=part number: 313A98E000 made by Locktite Inc. In Japan. Remove the fluid gasket from the case contact surface, EXT contact surface and wipe the contact surface with washer not to have any harmful oil or dusts.
Assembly the output shaft to the case.
Tighten the output shaft & companion flange installation bolts provisionally.
Tighten and attach the bracket that is fixing the terminal assembly connector at the same time.

Fig 27: Assembling Output Shaft To Case
Courtesy of KIA MOTORS AMERICA, INC.
Tighten the output shaft companion flange installation bolts at 50-54.9Nm (9) using the torque meter. The seal bolt part is tightened at 58 ~ 63Nm (1).

Fig 28: Tightening Output Shaft Companion Flange Bolts
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Apply vaseline to the seal ring of the drum support, and then assemble the direct clutch.

Fig 29: Applying Vaseline To Seal Ring Of Drum Support
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Make sure that both the drum support surface and the inner BOSS side of the clutch come almost to the same position.

Fig 30: Checking Clutch Position
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Mount the bearing with vaseline applied to the drum support surface.

Fig 31: Mounting Bearing With Vaseline Applied To Drum Support Surface
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Assemble the high & low reverse clutch.
CAUTION: Use the one with the same part number when replacing the high & low reverse clutch.

Fig 32: Assembling High & Low Reverse Clutch
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Align the spool lines of the high & low reveres clutch drive plate with a driver.

Fig 33: Aligning Spool Lines Of High & Low Reveres Clutch Drive Plate With Driver
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Assemble the rear sun gear and the high & low reverse clutch hub to the middle sun gear, and then fix it with the snap ring.
Mount the bearing race and bearing. (called "Middle gear sun-sub assembly")

CAUTION: Use the one with the same part number when replacing the middle sun gear.

Fig 34: Assembling Rear Sun Gear And High & Low Reverse Clutch Hub
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the middle sun gear-sub assembly.
Turn the middle sun gear right to left and press it until it fits to the position.

Fig 35: Assembling Middle Sun Gear-Sub Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Check the flange-combined part of the rear sun gear is approximately 2 mm(0.0787in.) lower than the high & low reverse clutch drum surface.
If there is no about 2mm(0.0787in.) of step height, it wont fit to the position. Remove it and try again.

Fig 36: Checking Distance
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Apply Vaseline to the bearing race, mount the rear carrier, and then assemble the rear carrier assembly.

Fig 37: Applying Vaseline To Bearing Race
Courtesy of KIA MOTORS AMERICA, INC.
Apply Vaseline to the bearing, and then assemble the middle carrier assembly.

Fig 38: Applying Vaseline To Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the input clutch, front carrier, and rear internal gear.

Fig 39: Assembling Input Clutch, Front Carrier, And Rear Internal Gear
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Assemble the input clutch to the rear internal gear.

Fig 40: Assembling Input Clutch To Rear Internal Gear
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Assemble the front carrier.

Fig 41: Assembling Front Carrier
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Fig 42: Automatic Transaxle System Overview
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Insert the snap ring to the slit in the front carrier.

Fig 43: Inserting Snap Ring To Slit In Front Carrier
Courtesy of KIA MOTORS AMERICA, INC.
Tighten the snap ring with the snap ring pliers, and then combine the front carrier to the rear internal gear. Loosen the snap ring and fix the front carrier and the rear internal gear at the same time.

Fig 44: Tightening Snap Ring
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Assemble the input clutch pack.

Fig 45: Assembling Input Clutch Pack
Courtesy of KIA MOTORS AMERICA, INC.
Apply vaseline to the seal ring of the input shaft.

Fig 46: Applying Vaseline To Seal Ring Of Input Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Exchange the end anchor pin, and attach provisionally.
Assemble the brake band provisionally. For band assembly, check "Brake band assembly* adjustment tips.".

Fig 47: Checking Brake Band Assembly Adjustment Tips
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Assemble the front sun gear.
Apply ATF to the bush section of the front sun gear and the end bearing section of the one-way clutch.

Fig 48: Assembling Front Sun Gear
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Adjust the leaning of the band using a wire as in the following figure so that the brake band is attached evenly with the front sun gear drum.

Fig 49: Adjusting Leaning Of Band
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Adjust the brake band attaching status based on "Brake band assembly * adjustment tips."
Brake band assembly-adjustment tips
- Tips for assembly
  1. Assemble so that indication mark post-assemble prevention becomes the SERVO side.
  2. Be careful not to lean the band when assembling. To prevent the band from being assembled askew, check that there is a gap between the band and drum while SERVO FREE.
- Brake band adjustment
Tighten Lock nut (31365 41X00), mount anchor end pin (31625 90X00) with 4 ~ 6 Nm(40 ~ 60 kg.cm, 3 ~ 4.4lb.ft) of torque, loosen 3 strokes, tighten lock nut with 40 ~ 51 Nm (400 ~ 510 kg.cm, 29.5 ~ 37.6lb.ft) of torque.
Check total end play.
For check tips, see " Total end play adjustment tips ."

NOTE: Total end play adjustment tips. Adjust with BRG-RACE so that clearance, L1 becomes 0.25 ~ 0.55mm(0.0098 ~ 0.0217in.).

Select the bearing race after checking end play when replacing the power train parts.

Check end play for flaw prevention also when not replacing the power train parts.
Apply ATF to the radial bearing.
Apply vaseline to the O-ring of the oil pump, bearing race.

Match the intake of the oil pump and the one of the case. Push in the oil pump attachment bolts with both hands until the surface of the oil pump and the one of the case become as high at the same time.

Remove the fluid gasket of the bolt on the left side (10), and then apply new fluid gasket (Threebond # 1215).

CAUTION: Make sure that fluid gasket does not touch the screw part.

Fig 50: Pushing In Oil Pump Attachment Bolts
Courtesy of KIA MOTORS AMERICA, INC.

Use the torque meter, tighten the bolts to the case with torque of 54.9 ~ 59.8 Nm(549 ~ 598kg.cm, 40.49 ~ 44.1lb.ft).

Apply AFT to the bush section of the oil pump.

Fig 51: Tightening Bolts

Courtesy of KIA MOTORS AMERICA, INC.

Total end play adjustment tips

Adjust with the bearing race so that clearance L1 becomes 0.25 ~ 0.55mm(0.0098 ~ 0.0217in.).

PART NUMBER AND DIMENSION REFERENCE

Bearing race part number	Dimension [mm(in.)]
45833-4C000	0.8 (0.0315)
45833-4C001	1.0 (0.0039)
45833-4C002	1.2 (0.0472)
45833-4C003	1.4 (0.0551)
45833-4C004	1.6 (0.0630)
45833-4C005	1.8 (0.0709)

Assemble the O-ring of the input shaft.

Fig 52: Assembling O-Ring Of Input Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Mount the converter housing to the case.
The notch comes to upward when having the oil pan upward.

Fig 53: Mounting Converter Housing To Case
Courtesy of KIA MOTORS AMERICA, INC.
Mount the housing converter tightening bolts.
After provisional tightening, use the torque meter and tighten them all with torque of 50 ~ 54.9Nm(500 ~ 549kg.cm, 36.9 ~ 40.5lbf.ft). (7).

The seal bolts are tightened with torque of 58 ~ 63Nm(580 ~ 630kg.cm, 42.8 ~ 46.5lbf.ft).

Fig 54: Mounting Housing Converter Tightening Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Check the brake band is not blocking the turbine sensor hole.

Fig 55: Checking Brake Band Is Not Blocking Turbine Sensor Hole
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Wipe with the whetstone so that oil does not stick to the contact surface with the oil pan of the case.

Fig 56: Wiping With Whetstone
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Spread the terminal assembly and the harness of the revolution sensor to the outer side of the case.

Fig 57: Spreading Terminal Assembly And Harness Of Revolution Sensor
Courtesy of KIA MOTORS AMERICA, INC.
Mount the control valve assembly.
Adhere the turbine sensor to the case installation surface so that the slit of the manual valve in the case hole fit in the curvature of the manual plate. (See the control valve installation figure)

Fig 58: Mounting Control Valve Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Tighten the control valve assembly and case installation bolts provisionally and the use the torque meter to tighten.
Tightening torque: 6.9 ~ 8.8 Nm(69 ~ 88 kg.cm, 5.1 ~ 6.5lb.ft)

CAUTION: Make sure that the harness does not get stuck in the case.

Fig 59: Tightening Control Valve Assembly And Case Installation Bolts
Courtesy of KIA MOTORS AMERICA, INC.

Mount the terminal assembly connector to the bracket.

Fig 60: Mounting Terminal Assembly Connector To Bracket

Courtesy of KIA MOTORS AMERICA, INC.

Control valve - case installation bolts position and tightening tips.

Fig 61: Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

Tighten bolts 1,2,3 of the figure above to prevent dislocation provisionally. After that, tighten them in order of 1-->2-->3 and then tighten the other bolts.

BOLT CODE AND SIZE REFERENCE

Code	Size mm(in.)	Bolt head	Count
A	42 (0.1654)	B	5
B	55 (0.2165)	7	6
C	40 (0.1575)	7	1

Mount to the control valve assembly to the case.

Fig 62: Identifying Turbine Sensor

Courtesy of KIA MOTORS AMERICA, INC.

Fig 63: Identifying Location Turbine Sensor Hole

Courtesy of KIA MOTORS AMERICA, INC.

Match the manual valve section part and the manual plate as shown in figure.

Fig 64: Matching Manual Valve Section Part And Manual Plate
Courtesy of KIA MOTORS AMERICA, INC.
Be careful when inserting the harness since the slit between the case and the control valve is small in the figure.

Fig 65: Precaution When Inserting Harness
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Connect the terminal assembly and the control valve assembly connector.

Fig 66: Connecting Terminal Assembly And Control Valve Assembly Connector
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Connect the temperature sensor connector.

Fig 67: Connecting Temperature Sensor Connector
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Connect the revolution sensor connector.

Fig 68: Connecting Revolution Sensor Connector
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Fix the revolution sensor harness to the control valve assembly with a clip.

Fig 69: Fixing Revolution Sensor Harness To Control Valve Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Fix the terminal assembly harness to the control valve assembly with a clip.

Fig 70: Fixing Terminal Assembly Harness To Control Valve Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Mount the oil pan gasket.
Match the mounting orientation to the hole.

Fig 71: Mounting Oil Pan Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Mount the oil pan.
Mount so that the drain bolt comes to the position of the figure on the left.

CAUTION: Make sure the harness does not get stuck.

Fig 72: Mounting Oil Pan
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Tighten the oil pan installation bolts provisionally, and then use the torque meter to tighten them with torque of 6.9 ~ 8.8 Nm (69 ~ 88kg.cm, 5.1 ~ 6.5 lbf.ft).

Fig 73: Tightening Oil Pan Installation Bolts
Courtesy of KIA MOTORS AMERICA, INC.
- Bolt assembly tips are as follows: Assemble in the following order.
  Assemble diagonally at first.
Fig 74: Assembling Sequence
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Mount the torque converter.
Check that the distance between the six point BOSS section and the converter housing section is 27.1mm(1.063in.).
NOTE:
Disassembly and assembly of oil pan drain bolts
- Disassembly
  Loosen the oil pan drain bolts and remove ATF. Discard the drain bolt washer (non-reusable)
- Reassembly
  Assemble the new drain bolt washer.
  
  Tighten the drain bolt with tightening torque of 29 ~ 39Nm(290 ~ 390kg.cm, 21.3 ~ 28.8lb.ft).