Transmission Reassembly

CAUTION: Apply the transaxle oil to the differential bearing outer race.

Install the differential assembly in the clutch housing.

Fig 1: Installing The Differential Assembly In The Clutch Housing
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
- Be sure not to damage the oil seal of the clutch housing side during installing the primary shaft.
- Apply the transaxle oil to the lips of the primary oil seal.
- Apply the transaxle oil to the secondary bearing outer race.
Install the primary shaft and the secondary shaft assembly in the clutch housing.

Fig 2: Installing The Primary Shaft And The Secondary Shaft Assemblies
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the 3rd/4th shift fork to the 3rd/4th clutch hub sleeve, insert the 5th/Rev shift rod into the shift fork and insert the 5th/Rev shift rod pin.

Fig 3: Identifying The 3rd/4th Shift Fork & 5th/Rev Shift Rod
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Use a new roll pin.
Align the 5th/Rev shift rod end with the 5th/Rev shift rod and insert the roll pin.
After inserting the 3rd/4th shift rod into the 3rd/4th shift fork, insert the 3rd/4th shift fork into the 3rd/4th shift rod end.
NOTE: Use a new roll pin.

Fig 4: Identifying 3rd/4th Shift Rod & 3rd/4th Shift Fork
Courtesy of KIA MOTORS AMERICA, INC.
Align the 3rd/4th shift rod end with the 3rd/4th shift rod and insert the roll pin.
Align the 3rd/4th shift rod with 3rd/4th shift fork and insert the roll pin.
Assemble the 1st/2nd shift fork to the 1st/2nd clutch hub sleeve, install the 1st/2nd shift rod.
NOTE: Use a new roll pin.

Fig 5: Identifying 1st/2nd Shift Fork & 1st/2nd Shift Rod
Courtesy of KIA MOTORS AMERICA, INC.
Align the 1st/2nd shift rod with the 1st/2nd shift fork and insert the roll pin.
NOTE: Use a new roll pin.
Align the 1st/2nd shift rod with the 1st/2nd shift fork and insert the roll pin.
NOTE: Use a new E-ring.
Insert the E-Ring into 5th/Rev shift rod.
Align the projection of the reverse shift lever with the 5th/Reverse shift rod end groove, and set the reverse shift lever to the clutch housing.
Install a new O-Ring to the reverse shift lever shaft.

Fig 6: Installing A New O-Ring To The Reverse Shift Lever Shaft
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Install the O-Ring so that it is on the outside.
Insert the reverse lever shaft into the reverse lever.

Fig 7: Inserting The Reverse Lever Shaft Into The Reverse Lever
Courtesy of KIA MOTORS AMERICA, INC.
Insert the pin.
After assembling the lever spring set, tighten bolts.
Tightening torque:

5.8~8.3 lb.ft (7.8~11.3 N.m, 80~115 kg.cm)
After installing the control case assembly, tighten bolts.
Tightening torque:

5.8~8.3 lb.ft (7.8~11.3 N.m, 80~115 kg.cm)

Fig 8: Installing The Control Case Assembly
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: When assembling the control case assembly, make sure to use the correct length bolt. Bolt A is longer than bolt B
Install the reverse idle shaft and the reverse idle gear.

Fig 9: Installing The Reverse Idle Shaft And Gear
Courtesy of KIA MOTORS AMERICA, INC.
Install the magnet.
NOTE: Thoroughly clean sealants from clutch housing and the transaxle case.
Apply a thin coat of sealant (Threebond#1216T or 1216TB) on the contacting surface of the clutch housing and the transaxle case.

Fig 10: Applying Sealant
Courtesy of KIA MOTORS AMERICA, INC.
Tighten the transaxle case mounting bolts.
Tightening torque:

13.7~18.8 lb.ft(18.6~25.5 N.m, 1.9~2.6 kg.cm)

Fig 11: Identifying Case Mounting Bolt Positions
Courtesy of KIA MOTORS AMERICA, INC.
Tighten the reverse idle shaft locking bolt to the transaxle case assembly.
Tightening torque:

13.7~18.8 lb.ft(18.6~25.5 N.m, 1.9~2.6 kg.cm)

Fig 12: Tightening The Reverse Idle Shaft Locking Bolt
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Since the length of detent springs are different, be sure to select the correct spring.
- The length of detent spring: 5th/Rev is longer than 1st/2nd, 3rd/4th.
- Apply sealant to the detent plug.
Insert the steel ball, spring and tighten the detent plug.
Tightening torque:

10.8~15 lb.ft (15~20 N.m, 1.5~2.1 kg.m)

Fig 13: Inserting The Steel Ball, Spring And Tighten The Detent Plug
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the secondary 5th gear.
NOTE:
- Since the shape of synchronizer ring are different, be sure to install correctly.
- There is missing synchronizer teeth in 3 places on the synchronizer ring of the reverse clutch hub assembly side.
Fig 14: Identifying Synchronizer Rings
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Pay attention for the assembling direction of 5th gear sleeve.
Install the 5th gear sleeve, 5th gear and the synchronizer ring.

Fig 15: Installing The 5th Gear Sleeve, 5th Gear And The Synchronizer Ring
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Assemble the oil groove of 5th clutch hub assembly to the 5th gear side.
After installing the 5th shift fork to the 5th clutch hub assembly, assemble the 5th clutch hub assembly and the 5th shift fork.

Fig 16: Assembling The 5th Clutch Hub Assembly And The 5th Shift Fork
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the synchronizer ring.
Assemble the reverse clutch cone and the reverse synchro sleeve at first, install it to the primary shaft.
CAUTION: Use a new roll pin.
Insert the roll pin to the 5th shift fork.

Fig 17: Installing Reverse Synchro Sleeve & Cone
Courtesy of KIA MOTORS AMERICA, INC.
To prevent the primary shaft from rotating, shift to 1st and 2nd gear.
Install SST (0K201 171 010) on the primary shaft.
CAUTION: Use a new lock nut.

Fig 18: Installing SST Onto The Primary Shaft
Courtesy of KIA MOTORS AMERICA, INC.
To prevent the lock nut from loosening after tightening it on to the primary shaft and secondary shaft, use caulking.
Tightening torque:

94~151 lb.ft (127~206 N.m, 13~21 kg.m)
Measure thrust clearance of the 5th gear and the reverse clutch cone with a dial indicator.
Clearance:

5th gear: 0.0029~0.0156 in (0.075~0.395 mm)

Reverse clutch cone: 0.004~0.01 in (0.1~0.25 mm)

Fig 19: Measuring 5th Gear Thrust Clearance
Courtesy of KIA MOTORS AMERICA, INC.

If not within the specification, reassemble the transaxle.

NOTE: Thoroughly clean sealants from the transaxle case and the rear cover.
Apply a thin coat of sealant (Threebond#1216 or 1216TB) to the contacting surface of the transaxle case and the rear cover.

Fig 20: Applying Sealant To Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the rear cover, making sure to align the stopper groove position of the reverse clutch cone. Tighten bolts.
Tightening torque:

5.8~8.3 lb.ft (7.8~11.3 N.m, 80~115 kg.cm)

Fig 21: Installing The Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.
Insert a washer onto the backup lamp switch and install the switch.
Tightening torque:

14~21.7 lb.ft (20~29.4 N.m, 2.0~3.0 kg.m)
Assemble the speed sensor to the speedometer driven gear.
Tightening torque:

5.8~8.3 lb.ft (7.8~11.3 N.m, 80~115 kg.cm)
Insert a bush to the change rod.

Fig 22: Installing Change Rod Bushing
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the release bearing and the release fork.
Remove the transaxle from the SST (0K130 175 011 A)
CAUTION: Do not damage the transaxle case.