Kia_Sephia_Rio_Spectra_Optima_1998-2006

Transaxle Removal & Installation

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2001-05 Rio



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Disconnect the negative, then positive battery cables.
  6.  
  7. Remove the fresh air duct.
  8.  
  9. Disconnect the input/turbine speed sensor, solenoid and transaxle range connector.
  10.  
  11. Remove the ground strap bolt and ground strap from the top of the transaxle.
  12.  
  13. Disconnect the Vehicle Speed Sensor (VSS) connector from the right side of the transaxle.
  14.  
  15. Remove the U-clip connecting the selector cable to the linkage.
  16.  
  17. Remove the nut and washer from the transaxle linkage.
  18.  
  19. Disconnect the Crankshaft Position (CKP) and Oxygen (O 2 ) sensor connectors.
  20.  
  21. Disconnect the 2 transaxle fluid cooler hoses.
  22.  
  23. Remove the top 2 upper converter housing bolts.
  24.  
  25. Support the engine with a suitable support bar.
  26.  
  27. Remove the front wheels.
  28.  
  29. Remove the splash shield.
  30.  
  31. Remove the 2 nuts from the U-bolt.
  32.  
  33. Remove the catalytic converter.
  34.  
  35. Remove the converter housing access cover and 4 drive plate-to-torque converter mounting nuts. You will need to rotate the engine using the crank pulley to get to all of the bolts.
  36.  
  37. Remove the lower starter bolt.
  38.  
  39. Remove the 4 oil pan-to-transaxle mounting bolts.
  40.  
  41. Separate the left tie rod end from the steering knuckle.
  42.  
  43. Remove the tension rod.
  44.  
  45. Separate the lower ball joint from the control arm.
  46.  
  47. Remove the No. 1 and 2 mounting nuts from the engine mounting member.
  48.  
  49. Remove the engine mounting member-to-chassis bolts and nuts and the member.
  50.  
  51. Remove the stabilizer bar and control link.
  52.  
  53. Remove the left halfshaft from the transaxle.
  54.  
  55. Install special tool 0K201 270 014 to prevent the side gear from becoming misaligned.
  56.  
  57. Remove the No. 2 engine mount from the transaxle.
  58.  
  59. Support and secure the transaxle with a suitable jack.
  60.  
  61. Remove the 2 remaining converter housing bolts from the front and rear sides of the transaxle
  62.  
  63. Remove the transaxle. Slowly lower the drivetrain, letting the transaxle tilt toward the ground. Carefully separate the transaxle from the engine and pull the unit out through the wheel well.
  64.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the automatic transaxle mounting-Rio

  1. Place the transaxle on a jack and place under the vehicle. Raise the transaxle into place and align with the engine.
  2.  
  3. Install the transaxle to engine, using 4 converter housing bolts (2 on top and 2 on bottom) to pull the components together. Torque the bolts to 47-66 ft. lbs. (64-89 Nm).

    Click image to see an enlarged view

    Fig. Location of the 4 converter housing bolts-Rio

  4.  
  5. Remove the jack.
  6.  
  7. Install the No. 2 engine mounting to the transaxle. Tighten the nut to 49-69 ft. lbs. (67-93 Nm) and the bolts to 32-40 ft. lbs. (43-54 Nm).
  8.  
  9. Install the starter and ground strap.
  10.  
  11. Install the 3 No. 1 engine mounting-to-chassis bolts and tighten to 32-46 ft. lbs. (43-52 Nm).
  12.  
  13. Install a new clip on the left driveshaft.
  14.  
  15. Install the driveshaft into the transaxle with the opening of the clip facing up.
  16.  
  17. Install the left lower ball joint to the spindle. Torque the pinch bolt to 40-50 ft. lbs. (54-68 Nm).
  18.  
  19. Install the stabilizer bar and control link and tighten to 32-45 ft. lbs. (43-61 Nm).
  20.  
  21. Install the tension rod. Install the front part of the tension rod to the body after inserting the bushing into the tensioner rod. Tighten to 87-108 ft. lbs. (118-147 Nm).
  22.  
  23. Install the engine-to-oil pan bolts and access cover. Torque the bolts to 27-38 ft. lbs. (37-52 Nm).
  24.  
  25. Install the drive plate-to-torque converter mounting nuts and torque to 25-36 ft. lbs. (34-49 Nm). Rotate the engine with the crank pulley to get to all of the nuts.
  26.  
  27. Install the engine mounting member-to-chassis nuts and bolts and tighten to 48-65 ft. lbs. (64-89 Nm).
  28.  
  29. Install the 2 nuts to the No. 1 and 2 engine mount-to-mounting member and tighten to 28-38 ft. lbs. (38-51 Nm).
  30.  
  31. Install the catalytic converter and U-clip. Torque to 27-38 ft. lbs. (37-52 Nm).
  32.  
  33. Install the splash shield.
  34.  
  35. Install the front wheels.
  36.  
  37. Connect the transaxle fluid hoses onto the cooler.
  38.  
  39. Remove the engine support bar.
  40.  
  41. Install the CKP and O 2 sensor connectors.
  42.  
  43. Install the solenoid valve connector.
  44.  
  45. Install the remaining components in the reverse of the removal procedure.
  46.  
  47. Fill the transaxle with the proper type and amount of fluid.
  48.  
  49. Test drive the vehicle. Check for proper operation in all gear ranges.
  50.  

2006 Rio & Spectra with 2.0L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transaxle oil.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Air intake assembly
     
    ECM connectors
     
    Battery tray
     
    Transaxle cooler hoses
     
    Ground cable from transaxle
     
    Transaxle wiring harnesses
     
    Transaxle shift cable
     
    Power steering hoses
     

  6.  
  7. Support the engine using Special Tool 09200-38001 support fixture.
  8.  
  9. Remove or disconnect the following:

    Front and rear roll stoppers
     
    Engine undercover
     
    Side cover
     
    Front tires
     
    Tie rod end
     
    Wheel speed sensor
     
    Caliper assembly
     
    Wheel knuckle mounting bolts
     
    Halfshaft from the transaxle
     
    Steering U-joint mounting bolt
     

  10.  
  11. Support the transaxle with a suitable jack.
  12.  
  13. Remove or disconnect the following:

    Sub-frame
     
    Starter mounting bolts
     
    Engine-to-torque converter mounting bolts
     
    Engine-to-transaxle mounting bolts
     

  14.  
  15. Remove the transaxle by lifting the vehicle.
  16.  
  17. Installation is the reverse of removal.
  18.  
  19. Note the following torques:
    1. Engine to transaxle mounting bolts-12mm: 43-58 ft. lbs. (60-80 Nm). 10mm: 32-41 ft. lbs. (43-55 Nm).
    2.  
    3. Engine-to-torque converter mounting bolts: 33-38 ft. lbs. (46-53 Nm).
    4.  

  20.  
  21. Fill the transaxle with fluid to the correct level.
  22.  

Optima



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Disconnect the control cable.
  8.  
  9. Disconnect the Vehicle Speed Sensor (VSS) connector.
  10.  
  11. Disconnect the transaxle range switch connector, solenoid connector and oil temperature sensor connector.
  12.  
  13. Disconnect the oil cooler hose.
  14.  
  15. Install a suitable engine support to the engine.
  16.  
  17. Remove the stabilizer bar, tie rod end, lower control arm ball joint and halfshafts.
  18.  
  19. Remove the steering gear box U-joint bolt and return tube mounting bolts.
  20.  
  21. Remove the sub-frame mounting bolts and sub-frame.
  22.  
  23. Remove the starter.
  24.  
  25. Remove the automatic transaxle mounting bolts.
  26.  
  27. Remove the engine-to-transaxle bolts. Place a jack under the transaxle.
  28.  
  29. Remove the transaxle from the vehicle.
  30.  
  31. Installation is the reverse of the removal procedure. Refer to the illustration for tightening specifications.
  32.  
  33. Fill the transaxle with fluid.
  34.  
  35. Check for proper clutch operation.

    Click image to see an enlarged view

    Fig. Automatic transaxle mounting and tightening specifications-Optima

  36.  

Sephia & Spectra with 1.8L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Disconnect the battery and battery cover.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the battery carrier.
  10.  
  11. Disconnect the solenoid and the Transaxle Range Switch (TRS) connectors.
  12.  
  13. Disconnect the selector cable.
  14.  
  15. Remove the Vehicle Speed Sensor (VSS) connector.
  16.  
  17. Remove the harness bracket.
  18.  
  19. Disconnect the throttle cable.
  20.  
  21. Remove the front wheels.
  22.  
  23. Remove the splash shields.
  24.  
  25. Remove the front exhaust pipe.
  26.  
  27. Remove the transverse member, if equipped.
  28.  
  29. Remove the tie-rod ends.
  30.  
  31. Remove the stabilizer control links.
  32.  
  33. Remove the lower arm by removing the cinch bolt from the lower arm ball joints. Pry the lower arm out of the knuckle.
  34.  
  35. Support the engine.
  36.  
  37. Remove the engine mounting member.
  38.  
  39. Remove the left and right halfshaft. Install Differential Side Gear holder K49A-4208-AT to hold the side gears.
  40.  
  41. Remove the joint shaft.
  42.  
  43. Remove the intake manifold bracket.
  44.  
  45. Remove the starter.
  46.  
  47. Remove the front engine/transaxle mount.
  48.  
  49. Remove the rear engine/transaxle mount.
  50.  
  51. Remove the inner and outer oil hoses.
  52.  
  53. Remove the side engine/transaxle mount.
  54.  
  55. Hold the drive plate and remove the converter nuts.
  56.  
  57. Support the transaxle on a jack.
  58.  
  59. Remove the transaxle mounting bolts.
  60.  
  61. Remove the transaxle.
  62.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the automatic transaxle assembly mounting and related components-Sephia

  1. Support the transaxle on a jack and lift it into place. Align the transaxle with the engine and install the mounting bolts. Tighten to 65-86 ft. lbs. (89-116 Nm).
  2.  
  3. Hold the driveplate and install the torque converter mount nuts. 26-36 ft. lbs. (35-49 Nm).
  4.  
  5. Install the side engine/transaxle mount. Loosely tighten the nuts of the transaxle side. Tighten the nuts and bolts of the body side to 32-44 ft. lbs. (44-60 Nm). Tighten the nuts of the transaxle side to 50-68 ft. lbs. (67-93 Nm).
  6.  
  7. Install the inner and outer oil hoses.
  8.  
  9. Install the rear engine/transaxle mount. Tighten the bolts to 50-68 ft. lbs. (67-93 Nm).
  10.  
  11. Install the front engine/transaxle mount. Tighten the mount bracket to the transaxle to 28-38 ft. lbs. (38-51 Nm). Loosely tighten the nuts and bolts of the engine mount rubber, then tighten to 50-68 ft. lbs. (67-98 Nm).
  12.  
  13. Install the starter.
  14.  
  15. Install the manifold bracket.
  16.  
  17. Install the joint shaft into the transaxle.
  18.  
  19. Install the joint shaft to the cylinder block and tighten the bolts in sequence (counterclockwise). Tighten to 32-46 ft. lbs. (42-62 Nm).
  20.  
  21. Install the halfshafts, be sure that the shafts are properly installed and do not pull out.
  22.  
  23. Install the engine mounting member, the mounting nuts/bolts and tighten the nuts/bolts at the far corners to 48-65 ft. lbs. (64-89 Nm), tighten the remaining 2 nuts to 28-38 ft. lbs. (38-51 Nm).
  24.  
  25. Install the front exhaust pipe.
  26.  
  27. Install the lower arm to the knuckle.
  28.  
  29. Install the stabilizer control link.
  30.  
  31. Install the tie-rod ends.
  32.  
  33. Install the transverse member, if removed.
  34.  
  35. Install the splash shields.
  36.  
  37. Install the wheels.
  38.  
  39. Connect the throttle cable.
  40.  
  41. Install the harness bracket.
  42.  
  43. Connect the VSS connector.
  44.  
  45. Connect the selector cable.
  46.  
  47. Connect the TRS connector.
  48.  
  49. Connect the solenoid connector.
  50.  
  51. Install the battery carrier.
  52.  
  53. Install the air cleaner assembly.
  54.  
  55. Install the battery and battery cover.
  56.  
  57. Fill the transaxle with the proper type and amount of fluid.
  58.  
  59. Test drive the vehicle. Check for proper operation in all gear ranges.
  60.  

 
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