Manual Transaxle: Reassembly

NOTE: Before reassembling, clean all parts in solvent, dry them, and apply lubricant to any contact surfaces.

Install the bushing (3EA) in the housing using the special tool.

Fig 1: Identifying Bushing
Courtesy of KIA MOTORS AMERICA, INC.
Install the input shaft front oil seal (A).
NOTE: Do not reuse the old oil seal.

Fig 2: Locating Input Shaft Front Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Install the dowel pin (3EA) into the groove of the housing surface.

Fig 3: Identifying Dowel Pin
Courtesy of KIA MOTORS AMERICA, INC.
Install the output shaft front oil guide (A).

Fig 4: Locating Output Shaft Oil Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the magnetic (A).

Fig 5: Locating Magnetic
Courtesy of KIA MOTORS AMERICA, INC.
Install the output outer race (A).

Fig 6: Locating Output Shaft Outer Race
Courtesy of KIA MOTORS AMERICA, INC.
Install the differential outer race (A).

Fig 7: Locating Differential Outer Race
Courtesy of KIA MOTORS AMERICA, INC.
Install the clutch release lever fulcrum bolt (A).

Fig 8: Locating Clutch Release Lever Fulcrum Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the differential oil seal (A) in the transaxle case using the special tool (09452-21200).

Fig 9: Identifying Special Tool (09452-21200)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 10: Locating Differential Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Install the differential gear assembly (A).

Fig 11: Locating Differential Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install the input shaft (A) and output shaft (B) in the clutch housing.

Fig 12: Locating Input Shaft And Output Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Install the bearing retainer. (Bolt: 4EA)
NOTE: Apply three bond 1303 equivalent around the hex bolt (4EA) before installing the bearing retainer (A).

TORQUE :

15-22 N.m (150-220 kgf.cm, 10-16 lbf.ft)

Fig 13: Locating Bearing Retainer
Courtesy of KIA MOTORS AMERICA, INC.
Install the 1 & 2 shift rail and fork assembly.
Install the 3 & 4, 5th shift rail and fork assembly.

Fig 14: Identifying Shift Rail And Fork Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install the spring pin.

Fig 15: Removing/Installing Spring Pin
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing, make sure that the slit of the spring pin is aligned within 15° of the center line of the shift rail.

Fig 16: Identifying Spring Pin Slit Alignment
Courtesy of KIA MOTORS AMERICA, INC.
Install the reverse shift lever (A). (Bolt:2EA)
TORQUE :

15-22 N.m (150-220 kgf.cm, 10-16 lbf.ft)

Fig 17: Locating Reverse Shaft Lever Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install the reverse idle gear assembly (A).

Fig 18: Locating Reverse Idle Gear Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive shaft oil seal (A) in the transaxle case using the special tool (09452-21200).

Fig 19: Locating Drive Shaft Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.

Fig 20: Installing Drive Shaft Oil Seal In Transaxle Case
Courtesy of KIA MOTORS AMERICA, INC.
Install the bushing (A) (3EA) in the transaxle case.

Fig 21: Locating Bushings
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil guide (A) in the transaxle case.

Fig 22: Locating Oil Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the input shaft oil guide (A).

Fig 23: Locating Input Shaft Oil Guide
Courtesy of KIA MOTORS AMERICA, INC.
Measure and choose the proper space as followed.

Fig 24: Measuring End Play
Courtesy of KIA MOTORS AMERICA, INC.

End play [in (mm)]: 0.0019T-0.0039T in (0.05T-0.10T mm)

Thickness of space [in (mm)] = (Height of housing [in (mm)] + Height of transaxle case [in (mm)]) - length of output [in (mm)] + end play [0.0003in (0.075mm)] + tolerance [0.0018in (0.045mm)]

NOTE: Measure the length of output shaft with both sides of bearing.
For keeping accuracy, measure at least 3 places and calculate the average value.

Install the output shaft space.

INPUT SIDE BEARING ADJUSTING SPACE

Parts Number	Thickness [in (mm)]
43227-28430	0.056 (1.43)
43227-28460	0.057 (1.46)
43227-28490	0.059 (1.49)
43227-28520	0.060 (1.52)
43227-28550	0.061 (1.55)
43227-28580	0.062 (1.58)
43227-28610	0.063 (1.61)
43227-28640	0.065 (1.64)
43227-28670	0.066 (1.67)
43227-28700	0.067 (1.70)
43227-28730	0.068 (1.73)
43227-28760	0.069 (1.76)
43227-28790	0.070 (1.79)
43227-28820	0.072 (1.82)
43227-28850	0.073 (1.85)
43227-28880	0.074 (1.88)
43227-28910	0.075 (1.91)

Install the output shaft rear outer race (A).

Fig 25: Locating Output Outer Race
Courtesy of KIA MOTORS AMERICA, INC.
Select the space of the differential assembly to minimize end play.

Fig 26: Measuring End Paly
Courtesy of KIA MOTORS AMERICA, INC.

End paly [in (mm)]: 0.0059T-0.0078T in (0.15T-0.20T mm)

Thickness of space [in (mm)] = (height of housing [in (mm)] + transaxle case [in (mm)]) - the length of differential [in (mm)] + end play [0.0007in (0.175mm)] + tolerance [0.0022in (0.055mm)]

NOTE: Measure the length of differential assembly with both sides of bearing.
For keeping accuracy, measure at least 3 places and the calculate average value.

Install the spacer of the differential assembly.

INPUT SIDE BEARING ADJUSTING SPACER

Parts Number	Thickness [in (mm)]
45835-22782	0.0295-0.0323 (0.75-0.82)
45835-22792	0.0327-0.0362 (0.83-0.92)
45835-22700	0.0366-0.0425 (0.93-1.00)
45835-22708	0.0398-0.0425 (1.01-1.08)
45835-22716	0.0429-0.0457 (1.09-1.16)

Fig 27: Identifying Spacer

Courtesy of KIA MOTORS AMERICA, INC.

Install the differential outer race (A).

Fig 28: Locating Differential Outer Race
Courtesy of KIA MOTORS AMERICA, INC.
Apply the specified sealant on the surface of the transaxle housing.
Specified sealant: MS 721-40

Fig 29: Identifying Sealant On Surface Of Transaxle Housing
Courtesy of KIA MOTORS AMERICA, INC.
Install transaxle case onto the transaxle housing. (Bolt:11EA)
NOTE: Use torque wrench when tightening bolt.

TORQUE :

43-55 N.m (430-550 kgf.cm, 32-40 lbf.ft)

Fig 30: Installing Transaxle Case Onto Transaxle Housing
Courtesy of KIA MOTORS AMERICA, INC.
Install bolt insides of the transaxle housing. (Bolt:3EA)
NOTE: Use torque wrench when tightening bolt.

TORQUE :

43-55 N.m (430-550 kgf.cm, 32-40 lbf.ft)

Fig 31: Installing Bolt Insides Of Transaxle Housing
Courtesy of KIA MOTORS AMERICA, INC.
Install the reverse idle bolt (A) to housing side.
TORQUE :

43-55 N.m (430-550 kgf.cm, 32-40 lbf.ft)

Fig 32: Locating Reverse Idle Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install filler plug (A).
TORQUE :

60-80 N.m (600-800 kgf.cm, 43-58 lbf.ft)

Fig 33: Locating Filler Plug
Courtesy of KIA MOTORS AMERICA, INC.
Install drain plug (A).
TORQUE :

60-80 N.m (600-800 kgf.cm, 43-58 lbf.ft)

Fig 34: Locating Drain Plug
Courtesy of KIA MOTORS AMERICA, INC.
Install 1 & 2, 3 & 4, 5th shift rail poppet bolt (A).
TORQUE :

30-35 N.m (300-350 kg.cm, 21-25 lb.ft)

Fig 35: Locating Shift Rail Poppet Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the control shift complete onto the transaxle case. (Bolt:6EA)
TORQUE :

30-35 N.m (300-350 kg.cm, 21-25 lb.ft)

NOTE: Use torque wrench when tightening bolt.

Fig 36: Installing Control Shift Complete Onto Transaxle Case
Courtesy of KIA MOTORS AMERICA, INC.
Install the shift cable bracket (A). (Bolt:2EA)
TORQUE :

20-27 N.m (200-270 kgf.cm, 15-20 lbf.ft)

Fig 37: Locating Shift Cable Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the clutch fork boot (A).

Fig 38: Locating Clutch Fork Boot
Courtesy of KIA MOTORS AMERICA, INC.
Install the release bearing (A) and clutch fork (B).

Fig 39: Locating Release Bearing And Clutch Fork
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Spread bearing sliding surface and holes of release fork with Grease.

Standard grease: CASMOLY L9508

Fig 40: Locating Bearing Sliding Surface And Holes Of Release Fork
Courtesy of KIA MOTORS AMERICA, INC.
Install the release cylinder (A). (Bolt:2EA)
TORQUE :

15-22 N.m (150-220 kgf.cm, 10-16 lbf.ft)

Fig 41: Locating Release Cylinder
Courtesy of KIA MOTORS AMERICA, INC.
Install the vehicle speed sensor (A). (Bolt 1EA)
TORQUE :

3-5 N.m (30-50 kg.cm, 2-4 lb-ft)

Fig 42: Locating Vehicle Speed Sensor
Courtesy of KIA MOTORS AMERICA, INC.