Kia Sportage 1998-02

Transmission Removal & Installation

Print

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Automatic transmission control cable from the throttle body
     

  8.  
  9. Slide the front seats forward and remove the 2 rear shift console mounting screws and set the parking brake.

    Rear console and slide the front seats rearward
     
    Front console mounting screws and untie the shifter boot draw strings
     
    Loosen the transfer case lock nut and remove the transfer case shifter lever knob
     
    Power/economy switch electrical connector
     
    Front console and shift the transfer lever to the 4L position
     
    transfer shift lever cover plate
     
    transfer case shift lever assembly and place the transmission in the park position
     
    Selector lever nuts
     
    Split pin from the shift selector lever
     
    Shift selector rod and spring washers
     
    Electrical connectors from the base of the selector lever
     

  10.  


NOTE
There is a fifth wire connection (Park Position). This wire is hard-wired, do not disconnect it.



Selector lever assembly
 
Control cable from the throttle linkage and slide the cable from the bellcrank
 
Upper dipstick tube from the lower dipstick tube
 
Input/Turbine speed sensor from the top rear of the transmission
 
Shift solenoids from the lower left side of the transmission
 
Vehicle Speed Sensor (VSS) from the center of the transfer case
 
Input speed sensor electrical connectors
 


Click image to see an enlarged view

Fig. Automatic transmission wiring connections

Matchmark the front and rear driveshafts. Remove the attaching bolts from both flanges and remove the driveshafts
 
Oil cooler pipes at the transmission
 


Click image to see an enlarged view

Fig. exploded view of the oil cooler pipe connections

Starter
 
Transfer case mounting bolts
 
Transfer case nuts from the crossmember and support the transmission
 
Crossmember
 
Transmission to engine mounting bolts
 
Front lower splash shield
 
Left side lower gusset
 
Torque converter inspection cover
 
Torque converter to drive plate bolts
 
Slide the transmission away from the engine and lower the transmission slightly
 
Crankshaft Position (CKP) sensor attaching bolt and sensor
 
4WD, 4WD LOW indicator switches and the VSS from the transfer case
 

  1. Lower the transmission. Be sure all wiring is clear and disconnected. Be sure the throttle cables come out without binding or attaching to anything.
  2.  

To install:

  1. Install or connect the following:

    Transmission into position to attach the sensor and indicator switch wiring. Be sure the throttle cables are guided into the engine compartment without binding or attaching to anything.
     
    4WD, 4WD LOW indicator switches and the VSS to the transfer case
     
    Input/turbine speed sensor and CKP sensor. Torque the bolt to 12 ft. lbs. (16 Nm).
     
    Raise the transmission and position it to the engine. Install the upper housing bolts. Torque the bolts in the following sequence:
     

  2.  
  3. 10mm bolts to 38-60 ft. lbs. (57-81 Nm).
  4.  
  5. 12mm bolts to 51-65 ft. lbs. (69-88 Nm).

    Exhaust hanger and bracket. Torque the bolts to 38-60 ft. lbs. (57-81 Nm).
     
    Oil cooler pipe to the lower engine mount. Torque the bolt to 60 ft. lbs. (81 Nm).
     
    Crossmember. Torque the bolts to 23-34 ft. lbs. (31-46 Nm).
     
    Two transfer case mounting bolts located at the right center of the transfer case. Torque the bolts to 23-34 ft. lbs. (31-46 Nm).
     
    Four transfer case nuts to the crossmember. Torque the nuts to 23-34 ft. lbs. (31-46 Nm).
     
    Torque converter-to-drive plate bolts. Torque the bolts to 12-20 ft. lbs. (16-27 Nm).
     
    Torque converter inspection cover. Torque the bolts to 41-62 inch lbs. (5-7 Nm).
     
    Front splash guard. Torque the bolts to 41-62 inch lbs. (5-7 Nm).
     
    Starter. Torque bolts to 27-40 ft. lbs. (37-54 Nm).
     
    Left side lower gusset. Torque the bolts to 38-60 ft. lbs. (57-81 Nm).
     
    Right side lower gusset in 3 steps:
     
    Install the bottom mounting bolts, but do not tighten.
     
    Install the top bolt to the intake manifold support bracket and manifold. Tighten to 27-40 ft. lbs. (37-54 Nm).
     
    Secure the manifold intake bracket by tightening the two attaching bolts to 38-60 ft. lbs. (57-81 Nm).
     

    1. Oil cooler pipes at the transmission. Torque the lines to 42-62 inch lbs. (5-7 Nm).
    2.  
    3. Two oil cooling tube clamps to the lines
    4.  
    5. Driveshafts with the matchmarks aligned. Torque the bolts to the differential flanges to 20-22 ft. lbs. (27-30 Nm) and the transfer case flange bolts to 36-43 ft. lbs. (49-59 Nm).
    6.  
    7. Undercover splash shield. Torque the bolts to 42-62 inch lbs. (5-7 Nm).
    8.  
    9. Upper dipstick tube to the lower tube and lower the vehicle
    10.  

  6.  
  7. Provide automatic transmission control cable slack by gently pulling the cable to the left until the cable pin has rotated sufficiently to line the automatic transmission control cable up with the slot in the rear of the throttle body bellcrank.
  8.  
  9. Slide the automatic transmission control cable and cable pin into the bellcrank.
  10.  
  11. Tighten the locknut.

    Throttle kickdown cable to the mounting bracket
     
    Automatic transmission control cable to the throttle body
     
    Air silencer
     
    Shifter lever assembly to the transfer case. Torque the bolts to 72-102 inch lbs. (22-28 Nm).
     
    Four wiring connectors under the shift selector lever
     
    Shift selector lever, do not exert any force when installing the shift selector lever
     
    Four shift selector lever nuts. Tighten to 72-102 inch lbs. (22-28 Nm).
     
    Shift rod and washers to the selector lever and install the split pin to the shift selector lever
     
    Power/Economy switch wiring connector
     
    Rear console
     
    Front console and tie the shift boot draw strings
     
    Negative battery cable
     

  12.  
  13. Fill the transmission to the proper level.
  14.  
  15. Fill the cooling system.
  16.  
  17. Start the vehicle, check for leaks, and repair if necessary.
  18.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section .
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Automatic transmission control cable from the throttle body
     

  8.  
  9. Slide the front seats forward and remove the 2 rear shift console mounting screws and set the parking brake.
    NOTE
    There is a fifth wire connection (Park Position). This wire is hard-wired, do not disconnect it.



    Rear console and slide the front seats rearward
     
    Front console mounting screws and untie the shifter boot draw strings
     
    Loosen the transfer case lock nut and remove the transfer case shifter lever knob
     
    Power/economy switch electrical connector
     
    Front console and shift the transfer lever to the 4L position
     
    transfer shift lever cover plate
     
    transfer case shift lever assembly and place the transmission in the park position
     
    Selector lever nuts
     
    Split pin from the shift selector lever
     
    Shift selector rod and spring washers
     
    Electrical connectors from the base of the selector lever
     



    Selector lever assembly
     
    Control cable from the throttle linkage and slide the cable from the bellcrank
     
    Upper dipstick tube from the lower dipstick tube
     
    Input/Turbine speed sensor from the top rear of the transmission
     
    Shift solenoids from the lower left side of the transmission
     
    Vehicle Speed Sensor (VSS) from the center of the transfer case
     
    Input speed sensor electrical connectors

    Click image to see an enlarged view

    Fig. Automatic transmission wiring connections

     
    Matchmark the front and rear driveshafts. Remove the attaching bolts from both flanges and remove the driveshafts
     
    Oil cooler pipes at the transmission

    Click image to see an enlarged view

    Fig. exploded view of the oil cooler pipe connections

     
    Starter
     
    Transfer case mounting bolts
     
    Transfer case nuts from the crossmember and support the transmission
     
    Crossmember
     
    Transmission to engine mounting bolts
     
    Front lower splash shield
     
    Left side lower gusset
     
    Torque converter inspection cover
     
    Torque converter to drive plate bolts
     
    Slide the transmission away from the engine and lower the transmission slightly
     
    Crankshaft Position (CKP) sensor attaching bolt and sensor
     
    4WD, 4WD LOW indicator switches and the VSS from the transfer case
     

  10.  
  11. Lower the transmission. Be sure all wiring is clear and disconnected. Be sure the throttle cables come out without binding or attaching to anything.
  12.  

To install:

  1. Install or connect the following:

    Transmission into position to attach the sensor and indicator switch wiring. Be sure the throttle cables are guided into the engine compartment without binding or attaching to anything.
     
    4WD, 4WD LOW indicator switches and the VSS to the transfer case
     
    Input/turbine speed sensor and CKP sensor. Torque the bolt to 12 ft. lbs. (16 Nm).
     
    Raise the transmission and position it to the engine. Install the upper housing bolts. Torque the bolts in the following sequence:
     

  2.  
  3. 10mm bolts to 38-60 ft. lbs. (57-81 Nm).
  4.  
  5. 12mm bolts to 51-65 ft. lbs. (69-88 Nm).

    Exhaust hanger and bracket. Torque the bolts to 38-60 ft. lbs. (57-81 Nm).
     
    Oil cooler pipe to the lower engine mount. Torque the bolt to 60 ft. lbs. (81 Nm).
     
    Crossmember. Torque the bolts to 23-34 ft. lbs. (31-46 Nm).
     
    Two transfer case mounting bolts located at the right center of the transfer case. Torque the bolts to 23-34 ft. lbs. (31-46 Nm).
     
    Four transfer case nuts to the crossmember. Torque the nuts to 23-34 ft. lbs. (31-46 Nm).
     
    Torque converter-to-drive plate bolts. Torque the bolts to 12-20 ft. lbs. (16-27 Nm).
     
    Torque converter inspection cover. Torque the bolts to 41-62 inch lbs. (5-7 Nm).
     
    Front splash guard. Torque the bolts to 41-62 inch lbs. (5-7 Nm).
     
    Starter. Torque bolts to 27-40 ft. lbs. (37-54 Nm).
     
    Left side lower gusset. Torque the bolts to 38-60 ft. lbs. (57-81 Nm).
     
    Right side lower gusset in 3 steps:
     

    1. Install the bottom mounting bolts, but do not tighten.
    2.  
    3. Install the top bolt to the intake manifold support bracket and manifold. Tighten to 27-40 ft. lbs. (37-54 Nm).
    4.  
    5. Secure the manifold intake bracket by tightening the two attaching bolts to 38-60 ft. lbs. (57-81 Nm).

      Oil cooler pipes at the transmission. Torque the lines to 42-62 inch lbs. (5-7 Nm).
       
      Two oil cooling tube clamps to the lines
       
      Driveshafts with the matchmarks aligned. Torque the bolts to the differential flanges to 20-22 ft. lbs. (27-30 Nm) and the transfer case flange bolts to 36-43 ft. lbs. (49-59 Nm).
       
      Undercover splash shield. Torque the bolts to 42-62 inch lbs. (5-7 Nm).
       
      Upper dipstick tube to the lower tube and lower the vehicle
       

    6.  

  6.  
  7. Provide automatic transmission control cable slack by gently pulling the cable to the left until the cable pin has rotated sufficiently to line the automatic transmission control cable up with the slot in the rear of the throttle body bellcrank.
  8.  
  9. Slide the automatic transmission control cable and cable pin into the bellcrank.
  10.  
  11. Tighten the locknut.

    Throttle kickdown cable to the mounting bracket
     
    Automatic transmission control cable to the throttle body
     
    Air silencer
     
    Shifter lever assembly to the transfer case. Torque the bolts to 72-102 inch lbs. (22-28 Nm).
     
    Four wiring connectors under the shift selector lever
     
    Shift selector lever, do not exert any force when installing the shift selector lever
     
    Four shift selector lever nuts. Tighten to 72-102 inch lbs. (22-28 Nm).
     
    Shift rod and washers to the selector lever and install the split pin to the shift selector lever
     
    Power/Economy switch wiring connector
     
    Rear console
     
    Front console and tie the shift boot draw strings
     
    Negative battery cable
     

  12.  
  13. Fill the transmission to the proper level.
  14.  
  15. Fill the cooling system.
  16.  
  17. Start the vehicle, check for leaks, and repair if necessary.
  18.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Automatic transmission control cable from the throttle body
     

  8.  
  9. Slide the front seats forward and remove the 2 rear shift console mounting screws and set the parking brake.
    NOTE
    There is a fifth wire connection (Park Position). This wire is hard-wired, do not disconnect it.



    Rear console and slide the front seats rearward
     
    Front console mounting screws and untie the shifter boot draw strings
     
    Loosen the transfer case lock nut and remove the transfer case shifter lever knob
     
    Power/economy switch electrical connector
     
    Front console and shift the transfer lever to the 4L position
     
    transfer shift lever cover plate
     
    transfer case shift lever assembly and place the transmission in the park position
     
    Selector lever nuts
     
    Split pin from the shift selector lever
     
    Shift selector rod and spring washers
     
    Electrical connectors from the base of the selector lever
     



    Selector lever assembly
     
    Control cable from the throttle linkage and slide the cable from the bellcrank
     
    Upper dipstick tube from the lower dipstick tube
     
    Input/Turbine speed sensor from the top rear of the transmission
     
    Shift solenoids from the lower left side of the transmission
     
    Vehicle Speed Sensor (VSS) from the center of the transfer case
     
    Input speed sensor electrical connectors

    Click image to see an enlarged view

    Fig. Automatic transmission wiring connections

     
    Matchmark the front and rear driveshafts. Remove the attaching bolts from both flanges and remove the driveshafts
     
    Oil cooler pipes at the transmission

    Click image to see an enlarged view

    Fig. Exploded view of the oil cooler pipe connections

     
    Starter
     
    Transfer case mounting bolts
     
    Transfer case nuts from the crossmember and support the transmission
     
    Crossmember
     
    Transmission to engine mounting bolts
     
    Front lower splash shield
     
    Left side lower gusset
     
    Torque converter inspection cover
     
    Torque converter to drive plate bolts
     
    Slide the transmission away from the engine and lower the transmission slightly
     
    Crankshaft Position (CKP) sensor attaching bolt and sensor
     
    4WD, 4WD LOW indicator switches and the VSS from the transfer case
     

  10.  
  11. Lower the transmission. Be sure all wiring is clear and disconnected. Be sure the throttle cables come out without binding or attaching to anything.
  12.  

To install:

  1. Install or connect the following:

    Transmission into position to attach the sensor and indicator switch wiring. Be sure the throttle cables are guided into the engine compartment without binding or attaching to anything.
     
    4WD, 4WD LOW indicator switches and the VSS to the transfer case
     
    Input/turbine speed sensor and CKP sensor. Torque the bolt to 12 ft. lbs. (16 Nm)
     
    Raise the transmission and position it to the engine. Install the upper housing bolts. Torque the bolts in the following sequence:
     

  2.  
  3. 10mm bolts to 38-60 ft. lbs. (57-81 Nm).
  4.  
  5. 12mm bolts to 51-65 ft. lbs. (69-88 Nm).

    Exhaust hanger and bracket. Torque the bolts to 38-60 ft. lbs. (57-81 Nm)
     
    Oil cooler pipe to the lower engine mount. Torque the bolt to 60 ft. lbs. (81 Nm)
     
    Crossmember. Torque the bolts to 23-34 ft. lbs. (31-46 Nm)
     
    Two transfer case mounting bolts located at the right center of the transfer case. Torque the bolts to 23-34 ft. lbs. (31-46 Nm)
     
    Four transfer case nuts to the crossmember. Torque the nuts to 23-34 ft. lbs. (31-46 Nm)
     
    Torque converter-to-drive plate bolts. Torque the bolts to 12-20 ft. lbs. (16-27 Nm)
     
    Torque converter inspection cover. Torque the bolts to 41-62 inch lbs. (5-7 Nm)
     
    Front splash guard. Torque the bolts to 41-62 inch lbs. (5-7 Nm)
     
    Starter. Torque bolts to 27-40 ft. lbs. (37-54 Nm)
     
    Left side lower gusset. Torque the bolts to 38-60 ft. lbs. (57-81 Nm)
     
    Right side lower gusset in 3 steps:
     

    1. Install the bottom mounting bolts, but do not tighten.
    2.  
    3. Install the top bolt to the intake manifold support bracket and manifold. Tighten to 27-40 ft. lbs. (37-54 Nm).
    4.  
    5. Secure the manifold intake bracket by tightening the two attaching bolts to 38-60 ft. lbs. (57-81 Nm).

      Oil cooler pipes at the transmission. Torque the lines to 42-62 inch lbs. (5-7 Nm)
       
      Two oil cooling tube clamps to the lines
       
      Driveshafts with the matchmarks aligned. Torque the bolts to the differential flanges to 20-22 ft. lbs. (27-30 Nm) and the transfer case flange bolts to 36-43 ft. lbs. (49-59 Nm)
       
      Undercover splash shield. Torque the bolts to 42-62 inch lbs. (5-7 Nm)
       
      Upper dipstick tube to the lower tube and lower the vehicle
       

    6.  

  6.  
  7. Provide automatic transmission control cable slack by gently pulling the cable to the left until the cable pin has rotated sufficiently to line the automatic transmission control cable up with the slot in the rear of the throttle body bellcrank.
  8.  
  9. Slide the automatic transmission control cable and cable pin into the bellcrank.
  10.  
  11. Tighten the locknut.

    Throttle kickdown cable to the mounting bracket
     
    Automatic transmission control cable to the throttle body
     
    Air silencer
     
    Shifter lever assembly to the transfer case. Torque the bolts to 72-102 inch lbs. (22-28 Nm)
     
    Four wiring connectors under the shift selector lever
     
    Shift selector lever, do not exert any force when installing the shift selector lever
     
    Four shift selector lever nuts. Tighten to 72-102 inch lbs. (22-28 Nm)
     
    Shift rod and washers to the selector lever and install the split pin to the shift selector lever
     
    Power/Economy switch wiring connector
     
    Rear console
     
    Front console and tie the shift boot draw strings
     
    Negative battery cable
     

  12.  
  13. Fill the transmission to the proper level.
  14.  
  15. Fill the cooling system.
  16.  
  17. Start the vehicle, check for leaks, and repair if necessary.
  18.  

 
label.common.footer.alt.autozoneLogo