Transmission Disassembly

CAUTION:

Clean transaxle exterior thoroughly with steam cleaner or cleaning solvent before disassembly.
Clean removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with compressed air.
Clean out all holes and passages with compressed air and verify that there are no obstructions.

WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to eyes. Wear protective eye wear whenever using compressed air.

Mount the transaxle on the SST (0K130 990 007/0K130 175 011A).

Fig 1: Mounting The Transaxle Onto The SST
Courtesy of KIA MOTORS AMERICA, INC.
Remove the release bearing and the release fork.
Remove the oil level gauge.
Remove the speed sensor.

Fig 2: Removing The Speed Sensor
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Remove the backup lamp switch.
Remove the rear cover.
NOTE: To remove the rear cover, lightly tap the rear cover using a plastic hammer.

Fig 3: Removing The Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Do not reuse the removed lock nut.
Lock the primary shaft with the SST (0K201 323 021).

Fig 4: Locking The Primary Shaft & Removing Lock Nut
Courtesy of KIA MOTORS AMERICA, INC.
Shift to 1 st or 2nd gear to lock the rotation of primary shaft.
Uncrimp the tabs of the locknuts.
Remove the lock nut from the primary and secondary shaft and remove the reverse clutch cone and the reverse synchronizer sleeve from the primary shaft.
CAUTION: Do not reuse the removed roll pin.
Remove the roll pin from the 5th shift fork with a pin punch.

Fig 5: Removing 5th Shift Fork Roll Pin
Courtesy of KIA MOTORS AMERICA, INC.
Remove the synchronizer ring and 5th shift fork, the 5th clutch hub assembly, 5th gear synchronizer ring, 5th gear sleeve at the same time.
Remove the secondary 5th gear.

Fig 6: Removing The Secondary 5th Gear
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After loosening the detent plug, remove the spring and the steel ball by using a magnetic stick.

Fig 7: Removing The Detent Plug, Spring And The Steel Ball
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Remove the reverse idle shaft lock bolt from the transaxle case assembly.
Remove the transaxle assembly.

Fig 8: Removing The Reverse Idle Shaft Lock Bolt
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: To remove the transaxle case, lightly tap the transaxle case using a plastic hammer.
Remove the magnet.
Remove the reverse idle shaft and the reverse idle gear.

Fig 9: Removing The Reverse Idle Shaft And The Reverse Idle Gear
Courtesy of KIA MOTORS AMERICA, INC.
Remove the control case assembly after loosening 3 bolts.

Fig 10: Removing The Control Case Assembly
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Remove the lever spring set.
After putting shift lever in neutral, remove the roll pin from the 1/2 shift fork using a pin punch.
NOTE: Do not reuse the removed roll pin.

Fig 11: Removing The Roll Pin From The 1/2 Shift Fork
Courtesy of KIA MOTORS AMERICA, INC.
Remove the 1/2 shift rod and the 1/2 shift fork.
After removing the roll pin from the 3/4 shift fork and the 3/4 shift rod end by using a pin punch, remove the 3/4 shift fork and shift rod end.

Fig 12: Removing The 3/4 Shift Fork And Shift Rod End
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Remove E-Ring from the 5/R shift rod.
After removing the roll pin from the 5/R shift rod end by using a pin punch, remove the 5/R shift rod and 5/R shift rod end.

Fig 13: Removing The 5/R Shift Rod And 5/R Shift Rod End
Courtesy of KIA MOTORS AMERICA, INC.
Remove the primary shaft geartrain and secondary shaft geartrain as an assembly.

Fig 14: Removing The Primary Shaft Geartrain And Secondary Shaft Geartrain As An Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Remove the differential assembly.

Fig 15: Removing The Differential Assembly

Courtesy of KIA MOTORS AMERICA, INC.