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.
Remove the fluid level gauge.
Remove the input (A) and the output speed sensor (B).

Fig 1: Identifying Input And Output Speed Sensor
Courtesy of KIA MOTORS AMERICA, INC.
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 2: Identifying Transaxle Range Switch And Manual Control Lever
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Remove the speedometer gear (or vehicle speed sensor (A).

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

Fig 4: Removing Valve Body Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the manual control shaft detent spring (A).

Fig 5: Identifying Manual Control Shaft Detent Spring
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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 6: Identifying Valve Body Mounting Bolts
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Remove the valve body and the steel balls (2EA).
CAUTION: Be careful not to lose the steel balls.
Remove the solenoid valve harness snap ring (A).

Fig 7: Identifying Solenoid Valve Harness Snap Ring
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Remove the solenoid valve harness.
Remove the strainer (A).

Fig 8: 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 9: Identifying 2ND Brake Retainer Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.

Remove each accumulator piston and spring.

LOW & REVERSE BRAKE NAME REFERENCE

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

Fig 10: Identifying Low & Reverse Brake, Under Drive Clutch, Over Drive Clutch And Second Brake

Courtesy of KIA MOTORS AMERICA, INC.

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

Fig 11: Identifying Snap Ring, Piston And Reduction Brake Accumulator And Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the snap ring (A) and the reduction brake piston cover assembly (B).
NOTE: Replace the O-rings (2EA) on the reduction brake piston cover assembly (B) with new ones when reassembling.

Fig 12: Identifying Snap Ring And Reduction Brake Piston Cover Assembly
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 13: Removing Snap Ring Inside First
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Fig 14: Identifying Reduction Brake Piston With Spring And Nut
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After pulling out the roller pin (A), remove the manual control shaft assembly (B) and the parking roller rod assembly (C).

Fig 15: Identifying Roller Pin
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Fig 16: Identifying Manual Control Shaft Assembly
Courtesy of KIA MOTORS AMERICA, INC.

Fig 17: Identifying Parking Roller Rod Assembly
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Loosen the torque converter housing mounting bolts (18EA) and remove the torque converter housing.
Remove the two O-rings (A) (2EA).

Fig 18: Identifying O-Rings
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Remove the differential assembly (A).

Fig 19: Identifying Differential Assembly
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Remove the main oil filter (B).

Fig 20: 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 21: Identifying Oil Pump 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 22: Identifying Thrust Washer
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Hold the input shaft with a hand and remove the underdrive clutch (B).

Fig 23: Identifying Underdrive Clutch
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Remove the thrust bearing (A).

Fig 24: Identifying Thrust Bearing
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Remove the underdrive clutch hub (A).

Fig 25: Identifying Underdrive Clutch Hub
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Remove the parking roller supporting shafts (B) (2EA).

Fig 26: Identifying Parking Roller Supporting Shafts
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Remove the parking roller support (A).

Fig 27: Identifying Parking Roller Support
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Remove the parking sprag shaft (A).

Fig 28: Identifying Parking Sprag Shaft
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Remove the parking sprag spring (B).

Fig 29: Identifying Parking Sprag Spring
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Remove the parking sprag (A).

Fig 30: Identifying Parking Sprag
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Remove the direct planetary carrier assembly (A).

Fig 31: Identifying Direct Planetary Carrier Assembly
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Remove the direct clutch assembly (A).

Fig 32: Identifying Direct Clutch Assembly
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Remove the reduction brake band (A).

Fig 33: Identifying Reduction Brake Band
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Remove the anchor plug (A) and a O-ring.

Fig 34: Identifying Anchor Plug
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Remove the thrust bearing (A) and race.

Fig 35: Identifying Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the rear cover (A) after loosening the mounting bolts (B).

Fig 36: Identifying Rear Cover And Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust race (A) and the seal rings (B) (4EA).

Fig 37: Identifying Thrust Race And Seal Rings
Courtesy of KIA MOTORS AMERICA, INC.
Remove the thrust bearing (A) and the O-rings (B) (6EA).

Fig 38: 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 39: Identifying Direct Accumulator Piston Assembly And Coil Spring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the reverse and overdrive clutch (A).

Fig 40: Identifying Reverse And Overdrive Clutch
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Remove the thrust bearing (A).

Fig 41: Identifying Thrust Bearing
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Remove the overdrive clutch hub (A) and the thrust bearing (B).

Fig 42: Identifying Overdrive Clutch Hub And Thrust Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the reverse sun gear (A).

Fig 43: Identifying Reverse Sun Gear
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Remove the planetary gear assembly (A).

Fig 44: Identifying Planetary Gear Assembly
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Remove the second brake snap ring and retainer (A).

Fig 45: Identifying Second Brake Snap Ring And Retainer
Courtesy of KIA MOTORS AMERICA, INC.
Remove the second brake return spring (A).

Fig 46: Identifying Second Brake Return Spring
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Remove the second brake pressure plate (A), brake discs (B) (4EA) and plates (C) (3EA).

Fig 47: 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 48: Identifying Brake Reaction Plate
Courtesy of KIA MOTORS AMERICA, INC.

Fig 49: Identifying Snap Ring
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Remove the low and reverse brake discs (A) (7EA) and plates (B) (6EA).

Fig 50: Identifying Low And Reverse Brake Discs And Plates
Courtesy of KIA MOTORS AMERICA, INC.
Remove the LR brake pressure plate (A).

Fig 51: Identifying LR Brake Pressure Plate
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Remove the wave spring (A).

Fig 52: Identifying Wave Spring
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Remove the snap ring (A) using SST (09453-3L110).

Fig 53: Removing Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the one way clutch inner race (A) and brake spring retainer (B).

Fig 54: Identifying One Way Clutch Inner Race
Courtesy of KIA MOTORS AMERICA, INC.

Fig 55: Identifying Brake Spring Retainer
Courtesy of KIA MOTORS AMERICA, INC.
Remove the LR brake return spring (A) and piston (B).

Fig 56: Identifying LR Brake Return Spring
Courtesy of KIA MOTORS AMERICA, INC.

Fig 57: 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 58: Identifying Snap Ring
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Fig 59: Identifying One Way Clutch
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Remove the seal rings (B) (2EA) and needle roller bearing (A).

Fig 60: 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 (7EA).
NOTE: After releasing the four bolts, first, find the others by revolving the gear.

Fig 61: Removing Transfer Drive Gear To Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the transfer drive gear (A).

Fig 62: Identifying Transfer Drive Gear
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Remove the differential bearing outer race (B) from the transaxle case (A).

Fig 63: 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 64: Identifying Differential Bearing Outer Race And Converter Housing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the differential oil seal (A).

Fig 65: Tapping Differential Oil Seal

Courtesy of KIA MOTORS AMERICA, INC.