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 oil.
  4.  
  5. Disconnect the negative, then positive battery cables.
  6.  
  7. Remove the coolant reservoir tank. Position it aside for access to the battery bracket.
  8.  
  9. Remove the battery bracket.
  10.  
  11. Remove the battery, battery tray and fixing holder.
  12.  
  13. Remove the fresh air duct and air cleaner assembly.
  14.  
  15. Remove the hose from the intake manifold.
  16.  
  17. Remove the Manifold Absolute Pressure (MAP) sensor connector.
  18.  
  19. Remove the air temperature sensor connector.
  20.  
  21. Remove the back-up switch connector from the connector bracket case.
  22.  
  23. Remove the Vehicle Speed Sensor (VSS) connector from the right side of the transaxle.
  24.  
  25. Remove the ground strap bolt and strap.
  26.  
  27. Remove the Crankshaft Position (CKP) sensor connector.
  28.  
  29. Remove the release lever, position the lever and clutch line aside.
  30.  
  31. Remove the upper starter mounting bolt.
  32.  
  33. Remove the 3 clutch housing bolts.
  34.  
  35. Support the engine with a suitable support bar.

    Click image to see an enlarged view

    Fig. Use the proper tool to support the engine-Rio

  36.  
  37. Remove the front wheels.
  38.  
  39. Remove the splash shields.
  40.  
  41. Remove the engine mounting member. The member is secured with 2 bolts and 4 nuts.
  42.  
  43. Remove the extension bar and shift control rod.
  44.  
  45. Remove the bolts from the No. 1 and No. 2 engine mounts and the mounts. There are 2 bolts for the No. 1 mount and 3 bolts for the No. 2 mount.
  46.  
  47. Remove the tension rod mounting nuts.
  48.  
  49. Remove the stabilizer bar and control link.
  50.  
  51. Separate the tie rod ends from the steering knuckle.
  52.  
  53. Remove the ball joint bolt and nut from the control arm, then separate the ball joint from the control arm.
  54.  
  55. Remove the halfshaft from the transaxle. Support the halfshaft with wire to prevent it from hanging unsupported.
  56.  
  57. Remove the starter lower mounting bolt and starter.
  58.  
  59. Remove the 3 lower clutch housing bolts, support the transaxle with a jack, then remove the 2 remaining bolts.
  60.  
  61. Carefully separate the transaxle from the engine and lower it.
  62.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the manual transaxle mounting and related components-Rio

  1. Raise the transaxle into position and seat it against the back of the engine. Install the transaxle-to-engine bolts and tighten as follows:
    1. Upper bolts (1-4): 47-66 ft. lbs. (64-89 Nm).
    2.  
    3. Lower bolts (5-8): 28-38 ft. lbs. (37-51 Nm).

      Click image to see an enlarged view

      Fig. Location of the manual transaxle-to-engine mounting bolts-Rio

    4.  

  2.  
  3. Remove the jack from the transaxle.
  4.  
  5. Install the starter and lower mounting bolt.
  6.  
  7. Install a new clip on the driveshaft.
  8.  
  9. Install the driveshaft into the transaxle with the opening of the clip pointing upward.
  10.  
  11. Install the lower ball joint into the steering knuckle. Torque the nut to 43-50 ft. lbs. (54-68 Nm).
  12.  
  13. Install the tie rod end to the steering knuckle. Torque the nut to 22-33 ft. lbs. (30-44 Nm). Install a new cotter pin.
  14.  
  15. Install the stabilizer bar and control link. Torque the retainers to 32-45 ft. lbs. (43-61 Nm).
  16.  
  17. Install the tension rod mounting nut and tighten to 87-108 ft. lbs. (118-147 Nm).
  18.  
  19. Install the No. 2 engine mount. Tighten the bolt to 32-40 ft. lbs. (43-54 Nm) and the nut to 49-69 ft. lbs. (67-93 Nm).
  20.  
  21. Install the No. 1 engine mount and tighten to 32-40 ft. lbs. (43-54 ft. lbs.).
  22.  
  23. Install the extension bar and shift control rod.
  24.  
  25. Install the transaxle pan drain plug.
  26.  
  27. Install the engine mounting member-to-chassis bolts and nuts. There are 2 bolt and 4 nuts. Torque the engine mounting member bolts and nuts to 47-66 ft. lbs. (64-89 Nm) and the No. 1 and 2 engine mount nuts to 27-38 ft. lbs. (37-52 Nm).
  28.  
  29. Install the splash shields.
  30.  
  31. Install the front wheels.
  32.  
  33. Remove the engine support bar.
  34.  
  35. Install the 3 clutch housing bolts and torque to 66-86 ft. lbs. (89-116 Nm).
  36.  
  37. Install the upper starter mounting bolts and tighten to 27-38 ft. lbs. (37-52 Nm).
  38.  
  39. Install the release lever.
  40.  
  41. Install the CKP sensor electrical connector.
  42.  
  43. Install the ground strap and bolt.
  44.  
  45. Install the VSS and back-up switch connectors.
  46.  
  47. Install the air cleaner assembly.
  48.  
  49. Install the air temperature and MAF sensor connectors.
  50.  
  51. Install the fresh air duct.
  52.  
  53. Install the hose from the intake manifold.
  54.  
  55. Install the coolant reservoir tank. Position it aside for access to the battery bracket.
  56.  
  57. Install the battery fixing holder, battery tray and battery.
  58.  
  59. Install the battery bracket.
  60.  
  61. Connect the Positive, then negative battery cables.
  62.  
  63. Fill the transaxle with fluid.
  64.  
  65. Check for proper clutch operation.
  66.  

2006 Rio



  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
     
    Ground cable from transaxle
     
    Transaxle wiring harnesses
     
    Transaxle shift cables
     
    Vehicle Speed Sensor (VSS)
     
    Back-up lamp switch connector
     
    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
     
    Transaxle upper mounting bolts from the engine
     
    Transaxle lower mounting bolts
     

  14.  
  15. Remove the transaxle by lifting the vehicle.
  16.  
  17. Installation is the reverse of removal.
  18.  
  19. Fill the transaxle with fluid to the correct level.
  20.  

Optima



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transaxle oil.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air duct.
  8.  
  9. Remove the air cleaner and air flow assembly.
  10.  
  11. Remove the back-up light switch connector.
  12.  
  13. Remove the clutch tube and clip.
  14.  
  15. Remove the clutch release cylinder.
  16.  
  17. Disconnect the speedometer cable.
  18.  
  19. Disconnect the select cable and shift cable.
  20.  
  21. Remove the starter mounting bolts.
  22.  
  23. Remove the upper transaxle mounting bolts.
  24.  
  25. Install engine hooks and support the engine with a suitable support bar.
  26.  
  27. Remove the transaxle mounting bracket and insulator.
  28.  
  29. Remove the front wheels.
  30.  
  31. Remove the steering gear box U-joint bolt and return tube mounting bolts.
  32.  
  33. Remove the muffler.
  34.  
  35. Remove the sub-frame mounting bolts and sub-frame.
  36.  
  37. Remove the transaxle front and rear mounting bracket.
  38.  
  39. Remove the transaxle side mounting bolts. Support the transaxle with a jack.
  40.  
  41. Remove the transaxle from the vehicle.
  42.  
  43. Installation is the reverse of the removal procedure. Refer to the illustration for tightening specifications.
  44.  
  45. Fill the transaxle with fluid.
  46.  
  47. Check for proper clutch operation.

    Click image to see an enlarged view

    Fig. Manual transaxle mounting and tightening specifications-Optima

  48.  

Sephia & Spectra with 1.8L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transaxle oil.
  4.  
  5. Remove the battery box and disconnect the battery.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the battery carrier.
  10.  
  11. Remove the back-up light switch and the bracket.
  12.  
  13. Disconnect the ground strap from the top of the transaxle.
  14.  
  15. Disconnect the neutral switch connector and the Vehicle Speed Sensor (VSS) connector.
  16.  
  17. Remove the wire harness bracket and ground cable.
  18.  
  19. Remove the Crankshaft Position (CKP) sensor.
  20.  
  21. Remove the wheels.
  22.  
  23. Remove the splash shield.
  24.  
  25. Remove the transverse member.
  26.  
  27. Remove the extension bar and the change control rod.
  28.  
  29. Remove the tie-rod ends.
  30.  
  31. Remove the stabilizer control link.
  32.  
  33. Remove the halfshaft and the joint shaft.
  34.  
  35. Remove the intake manifold bracket.
  36.  
  37. Remove the starter.
  38.  
  39. Remove the front exhaust pipe.
  40.  
  41. Support the engine and remove the engine mounting member.
  42.  
  43. Remove the rear engine/transaxle mount.
  44.  
  45. Remove the front engine/transaxle mount.
  46.  
  47. Remove the clutch release cylinder.
  48.  
  49. Remove the side engine/transaxle mount.
  50.  
  51. Support the transaxle on a jack
  52.  
  53. Remove the transaxle mounting bolts.
  54.  
  55. Remove the transaxle.

    Click image to see an enlarged view

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

  56.  

To install:

  1. Install the transaxle into position and install the mounting bolts. Tighten to 28-38 ft. lbs. (37-52 Nm).
  2.  
  3. Remove the support jack.
  4.  
  5. Install the side mount. Tighten the body side nuts and bolts to 32-44 ft. lbs. (44-60 Nm). Tighten the transaxle side nuts to 50-68 ft. lbs. (67-93 Nm).
  6.  
  7. Install the clutch release cylinder.
  8.  
  9. Install the front mount, loosely tighten the mount nut and bolt.
  10.  
  11. Install the rear mount, align and set all bolts, then tighten to 50-68 ft. lbs. (67-93 Nm).
  12.  
  13. Install the engine mounting member. Tighten the 4 outer nuts and bolts to 50-65 ft. lbs. (67-89 Nm) and the 2 remaining nuts to 28-38 ft. lbs. (38-51 Nm).
  14.  
  15. Tighten the front mount nut and bolt to 50-68 ft. lbs. (67-93 Nm).
  16.  
  17. Install the starter.
  18.  
  19. Install the manifold bracket and front exhaust pipe.
  20.  
  21. Install the joint shaft and the halfshaft.
  22.  
  23. Install the stabilizer control link.
  24.  
  25. Install the tie-rod ends.
  26.  
  27. Install the control rod and extension bar.
  28.  
  29. Install the transverse member.
  30.  
  31. Install the splash shield.
  32.  
  33. Install the wheels.
  34.  
  35. Install the harness bracket.
  36.  
  37. Install the CKP sensor.
  38.  
  39. Install the VSS and the neutral switch connectors.
  40.  
  41. Install the back-up light switch connector bracket and the switch.
  42.  
  43. Install the No. 4 engine mount.
  44.  
  45. Install the battery carrier.
  46.  
  47. Install the air cleaner assembly.
  48.  
  49. Install the battery and battery box.
  50.  
  51. Fill the transaxle with fluid.
  52.  
  53. Check for proper clutch operation.
  54.  

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:

    Negative battery cable
     
    Battery heat shield
     
    Battery and battery tray
     
    Air intake assembly
     
    Back-up lamp switch connector
     
    Clutch release cylinder
     
    Shift cables
     
    Vehicle speed sensor
     
    Starter mounting bolts
     
    Transaxle upper mounting bolts to the engine
     

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

    Transaxle mounting bracket
     
    Front tire
     
    Tie rod end
     
    Wheel speed sensor
     
    Wheel knuckle mounting bolts
     
    Caliper assembly
     
    Halfshaft
     
    Steering U-joint mounting bolt
     
    Oxygen sensor
     
    Front muffler
     
    Power steering hoses
     
    Front and rear roll stoppers
     

  10.  
  11. Using a suitable jack, support the sub-frame assembly.
  12.  
  13. Remove the sub -frame.
  14.  
  15. Using a suitable jack, support the transaxle assembly.
  16.  
  17. Remove the transaxle lower mounting bolts.
  18.  
  19. Lower the transaxle assembly.
  20.  
  21. Installation is the reverse order of removal.
  22.  
  23. Fill the transaxle to the correct level.
  24.  

 
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