Kia_Sedona_2002-2006

Transaxle Removal & Installation

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3.5L Engine



  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Record the radio anti theft code data.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the transaxle fluid.
  8.  
  9. Remove or disconnect the following:

    Battery and tray
     
    Engine wiring harness
     
    Transaxle wiring harness
     
    Air filter assembly
     
    Shift cable
     
    Transaxle cooler lines
     
    Radiator hoses
     
    Radiator
     
    Heater hoses
     
    Steering intermediate shaft
     
    Power steering pressure and return lines from the steering gear
     
    Engine upper roll stopper and bracket
     
    Front wheels
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Front muffler
     
    Outer tie rod ends
     
    Lower ball joints
     
    Axle halfshafts
     
    Steering tube mounting bolt
     

  10.  
  11. Support the engine from below.

    Front subframe
     
    Starter motor
     
    Transaxle housing cover
     

  12.  
  13. Support the transaxle with a transmission jack.

    Torque converter bolts
     
    Transaxle flange bolts
     
    Transaxle
     

  14.  

To install:

  1. Install or connect the following:

    Transaxle. Tighten the flange bolts to 29-38 ft. lbs. (42-54 Nm)
     
    Torque converter bolts
     
    Transaxle housing cover
     
    Starter motor
     
    Front subframe
     
    Steering tube mounting bolt
     
    Axle halfshafts
     
    Lower ball joints
     
    Outer tie rod ends
     
    Front muffler
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Front wheels
     
    Engine upper roll stopper and bracket
     
    Power steering pressure and return lines from the steering gear
     
    Steering intermediate shaft
     
    Heater hoses
     
    Radiator
     
    Radiator hoses
     
    Transaxle cooler lines
     
    Shift cable
     
    Air filter assembly
     
    Transaxle wiring harness
     
    Engine wiring harness
     
    Battery and tray
     

  2.  
  3. Fill the transaxle to the correct level with the proper transmission fluid.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  
  9. Reprogram the radio anti theft codes.
  10.  

3.8L Engine



  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Record the radio anti theft code data.
  4.  
  5. Disconnect the negative battery cable. Disconnect the positive battery cable. Remove the battery.
  6.  
  7. Disconnect the AFS connector. Remove the air cleaner upper cover. Remove the air cleaner assembly.
  8.  
  9. Disconnect the air cleaner hose. Remove the battery tray retaining bolts. Remove the battery tray.
  10.  
  11. Remove the inhibiter switch connector wire. Remove the solenoid valve connector wire. Remove the input speed sensor connector wire.
  12.  
  13. Remove the vehicle speed sensor connector wire. Remove the CKP sensor connector wire.
  14.  
  15. Disconnect and plug the transaxle fluid cooler hoses from the transaxle lines. Remove the upper transaxle mounting bolts.
  16.  
  17. Using tool SST(09200-38001) or equivalent, hold the engine and transaxle assembly in position.

    Click image to see an enlarged view

    Fig. Engine/transaxle support tool installation-3.8L Engine

  18.  
  19. Remove the transaxle insulator mounting bolt.
  20.  
  21. Raise and safely support the vehicle. Remove the front tires. Remove the power steering column joint bolt.
  22.  
  23. Remove the engine/transaxle under cover. Drain the transaxle fluid. Drain the power steering fluid, through the return line. Disconnect the power steering pressure tube from the power steering oil pump.
  24.  
  25. Disconnect the lower arm, the tie rod end ball joint and the stabilizer bar link from the front knuckle.
  26.  
  27. Remove the roll stopper mounting bolts. Remove the mounting bolts from the subframe, by supporting the subframe with a jack. As necessary, remove the starter.
  28.  
  29. Remove the driveshaft from the transaxle. Position a jack, for support, under the transaxle assembly.
  30.  
  31. Remove the transaxle under mounting bolts. Remove the driveplate bolts.
  32.  
  33. Lifting the vehicle up and lowering the jack slowly, remove the transaxle assembly.
  34.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Torque the lower transaxle to engine mounting bolts to 47-62 ft. lbs. (65-85 Nm).
  4.  
  5. Torque the upper transaxle to engine mounting bolts to 47-62 ft. lbs. (65-85 Nm).
  6.  
  7. Torque the roll stopper mounting bolts to 65-80 ft. lbs. (90-110 Nm).
  8.  
  9. Torque the transaxle insulator engine mounting bolt to 65-80 ft. lbs. (90-110 Nm).
  10.  
  11. Fill the transaxle with the proper grade and type transaxle fluid.
  12.  
  13. Run the engine and recheck the transaxle fluid. Roadtest the vehicle.
  14.  
  15. Reprogram the radio anti theft codes.
  16.  

 
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