Kia Sportage 1998-02

Transmission Removal & Installation

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NOTE
The removal of the manual transmission is virtually the same for 4WD and 2WD vehicles.

  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 transfer case.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Rear portion of the center console
     
    Shift lever and transfer lever knobs
     
    Slide the boot cover over the shifters and remove the center console
     
    Shift lever
     
    Transfer lever
     
    Front driveshaft by removing the bolts at the front differential and the bolts at the transfer case, if equipped
     
    Bolts from the rear differential flange and the center support. Pull the driveshaft out of the tail shaft housing, if equipped with a 4 x 4
     
    Bolts from the rear differential flange and center support. Pull the driveshaft out of the tail shaft housing, if equipped with a 4 x 2
     
    Back-up light electrical connector and the Vehicle Speed Sensor (VSS) electrical connectors and move the wire harness aside
     
    Crankshaft Position (CKP) sensor from the transmission housing
     
    Clutch release cylinder and move it aside
     
    Front exhaust pipe bracket
     
    Front lower transmission housing bolts
     
    Transfer case side mount, if equipped and properly support the transmission
     
    Transmission crossmember
     
    transmission mount bolts
     
    Starter from the front housing
     
    Transmission and transfer case, if equipped
     

  8.  

To install:

  1. Install or connect the following:

    Transmission into position at the rear of the engine
     
    Wire harness along the right side of the transmission and route the VSS wire over the transmission to the rear of the control rod extension
     
    Transmission to engine 14mm mounting bolts. Torque the bolts to 80 ft. lbs. (108 Nm).
     
    Transmission to engine 10mm mounting bolts. Torque the bolts to 29 ft. lbs. (39 Nm).
     
    Transmission to engine 6mm mounting bolts. Torque the bolts to 5 ft. lbs. (7 Nm).
     
    Exhaust pipe to the bracket. Torque the bolts to 20 ft. lbs. (27 Nm).
     
    Starter and ground wire. Torque the bolts to 29 ft. lbs. (39 Nm).
     
    Transmission crossmember mount. Torque the bolts to 80 ft. lbs. (108 Nm).
     
    Crossmember to the chassis. Torque the bolts to 32 ft. lbs. (44 Nm).
     
    CKP sensor. Torque the bolt to 5 ft. lbs. (7 Nm).
     
    4WD indicator switch connector
     
    Back-up light electrical connector
     
    VSS electrical connector
     
    Clutch release cylinder. Torque the bolts to 29 ft. lbs. (39 Nm).
     
    Driveshaft to the rear differential flange, 4 x 4 only
     
    Forward end of the driveshaft into the extension housing and attach the center support to the chassis
     
    Shaft to the rear differential flange. Torque the bolts to 27 ft. lbs. (36 Nm).
     
    Front driveshaft at the transfer case and install the bolts to the front differential, 4 x 4 only
     
    Transfer case side mount, if equipped. Torque the bolts to 38 ft. lbs. (52 Nm).
     
    Transfer case side mount to the chassis. Torque the bolts to 38 ft. lbs. (52 Nm).
     
    Shift lever assembly. Torque the shift lever bracket bolts to 18 ft. lbs. (25 Nm).
     
    Transfer lever assembly, if equipped. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Dust cover plate over the shifter lever handles. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Front console
     
    Shifter lever knobs
     
    Negative battery cable
     
    Fill the transfer case.
     

  2.  
  3. Fill the transmission assembly.
  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  


NOTE
The removal of the manual transmission is virtually the same for 4WD and 2WD vehicles.

  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 transfer case.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Rear portion of the center console
     
    Shift lever and transfer lever knobs
     
    Slide the boot cover over the shifters and remove the center console
     
    Shift lever
     
    Transfer lever
     
    Front driveshaft by removing the bolts at the front differential and the bolts at the transfer case, if equipped
     
    Bolts from the rear differential flange and the center support. Pull the driveshaft out of the tail shaft housing, if equipped with a 4 x 4
     
    Bolts from the rear differential flange and center support. Pull the driveshaft out of the tail shaft housing, if equipped with a 4 x 2
     
    Back-up light electrical connector and the Vehicle Speed Sensor (VSS) electrical connectors and move the wire harness aside
     
    Crankshaft Position (CKP) sensor from the transmission housing
     
    Clutch release cylinder and move it aside
     
    Front exhaust pipe bracket
     
    Front lower transmission housing bolts
     
    Transfer case side mount, if equipped and properly support the transmission
     
    Transmission crossmember
     
    transmission mount bolts
     
    Starter from the front housing
     
    Transmission and transfer case, if equipped
     

  8.  

To install:

  1. Install or connect the following:

    Transmission into position at the rear of the engine
     
    Wire harness along the right side of the transmission and route the VSS wire over the transmission to the rear of the control rod extension
     
    Transmission to engine 14mm mounting bolts. Torque the bolts to 80 ft. lbs. (108 Nm).
     
    Transmission to engine 10mm mounting bolts. Torque the bolts to 29 ft. lbs. (39 Nm).
     
    Transmission to engine 6mm mounting bolts. Torque the bolts to 5 ft. lbs. (7 Nm).
     
    Exhaust pipe to the bracket. Torque the bolts to 20 ft. lbs. (27 Nm).
     
    Starter and ground wire. Torque the bolts to 29 ft. lbs. (39 Nm).
     
    Transmission crossmember mount. Torque the bolts to 80 ft. lbs. (108 Nm).
     
    Crossmember to the chassis. Torque the bolts to 32 ft. lbs. (44 Nm).
     
    CKP sensor. Torque the bolt to 5 ft. lbs. (7 Nm).
     
    4WD indicator switch connector
     
    Back-up light electrical connector
     
    VSS electrical connector
     
    Clutch release cylinder. Torque the bolts to 29 ft. lbs. (39 Nm).
     
    Driveshaft to the rear differential flange, 4 x 4 only
     
    Forward end of the driveshaft into the extension housing and attach the center support to the chassis
     
    Shaft to the rear differential flange. Torque the bolts to 27 ft. lbs. (36 Nm).
     
    Front driveshaft at the transfer case and install the bolts to the front differential, 4 x 4 only
     
    Transfer case side mount, if equipped. Torque the bolts to 38 ft. lbs. (52 Nm).
     
    Transfer case side mount to the chassis. Torque the bolts to 38 ft. lbs. (52 Nm).
     
    Shift lever assembly. Torque the shift lever bracket bolts to 18 ft. lbs. (25 Nm).
     
    Transfer lever assembly, if equipped. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Dust cover plate over the shifter lever handles. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Front console
     
    Shifter lever knobs
     
    Negative battery cable
     
    Fill the transfer case.
     

  2.  
  3. Fill the transmission assembly.
  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  


NOTE
The removal of the manual transmission is virtually the same for 4WD and 2WD vehicles.

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

    Negative battery cable
     
    Rear portion of the center console
     
    Shift lever and transfer lever knobs
     
    Slide the boot cover over the shifters and remove the center console
     
    Shift lever
     
    Transfer lever
     
    Front driveshaft by removing the bolts at the front differential and the bolts at the transfer case, if equipped
     
    Bolts from the rear differential flange and the center support. Pull the driveshaft out of the tail shaft housing, if equipped with a 4X4.
     
    Bolts from the rear differential flange and center support. Pull the driveshaft out of the tail shaft housing, if equipped with a 4X2.
     
    Back-up light electrical connector and the Vehicle Speed Sensor (VSS) electrical connectors and move the wire harness aside
     
    Crankshaft Position (CKP) sensor from the transmission housing
     
    Clutch release cylinder and move it aside
     
    Front exhaust pipe bracket
     
    Front lower transmission housing bolts
     
    Transfer case side mount, if equipped and properly support the transmission
     
    Transmission crossmember
     
    transmission mount bolts
     
    Starter from the front housing
     
    Transmission and transfer case, if equipped
     

  8.  

To install:

  1. Install or connect the following:

    Transmission into position at the rear of the engine
     
    Wire harness along the right side of the transmission and route the VSS wire over the transmission to the rear of the control rod extension
     
    Transmission to engine 14mm mounting bolts. Torque the bolts to 80 ft. lbs. (108 Nm)
     
    Transmission to engine 10mm mounting bolts. Torque the bolts to 29 ft. lbs. (39 Nm)
     
    Transmission to engine 6mm mounting bolts. Torque the bolts to 5 ft. lbs. (7 Nm)
     
    Exhaust pipe to the bracket. Torque the bolts to 20 ft. lbs. (27 Nm)
     
    Starter and ground wire. Torque the bolts to 29 ft. lbs. (39 Nm)
     
    Transmission crossmember mount. Torque the bolts to 80 ft. lbs. (108 Nm)
     
    Crossmember to the chassis. Torque the bolts to 32 ft. lbs. (44 Nm)
     
    CKP sensor. Torque the bolt to 5 ft. lbs. (7 Nm)
     
    4WD indicator switch connector
     
    Back-up light electrical connector
     
    VSS electrical connector
     
    Clutch release cylinder. Torque the bolts to 29 ft. lbs. (39 Nm)
     
    Driveshaft to the rear differential flange, 4 x 4 only
     
    Forward end of the driveshaft into the extension housing and attach the center support to the chassis
     
    Shaft to the rear differential flange. Torque the bolts to 27 ft. lbs. (36 Nm)
     
    Front driveshaft at the transfer case and install the bolts to the front differential, 4 x 4 only
     
    Transfer case side mount, if equipped. Torque the bolts to 38 ft. lbs. (52 Nm)
     
    Transfer case side mount to the chassis. Torque the bolts to 38 ft. lbs. (52 Nm)
     
    Shift lever assembly. Torque the shift lever bracket bolts to 18 ft. lbs. (25 Nm)
     
    Transfer lever assembly, if equipped. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    Dust cover plate over the shifter lever handles. Torque the bolts to 15 ft. lbs. (20 Nm)
     
    Front console
     
    Shifter lever knobs
     
    Negative battery cable
     
    Fill the transfer case.
     

  2.  
  3. Fill the transmission assembly.
  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

 
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