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Manual Transaxle: Disassembly

  1. Remove the vehicle speed sensor (A). (Bolt: 1EA)
    Fig 1: Locating Vehicle Speed Sensor
    G04864745Courtesy of KIA MOTORS AMERICA, INC.
  2. Remove the release cylinder (A) tube from the release cylinder.
  3. Remove the release cylinder from the transaxle. (Bolt: 2EA)
    Fig 2: Locating Release Cylinder
    G04864746Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the release bearing (A) and clutch fork (B).
    Fig 3: Locating Release Bearing And Clutch Fork
    G04864747Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the clutch fork boot (A).
    Fig 4: Locating Clutch Fork Boot
    G04864748Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the shift cable bracket (A). (Bolt:2EA)
    Fig 5: Locating Shift Cable Bracket
    G04864749Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the control shift complete (A) from the transaxle case. (Bolt:6EA)
    Fig 6: Locating Control Shift
    G04864750Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the shift rail poppet bolt (A) (3EA).
    Fig 7: Locating Shift Rail Poppet Bolt
    G04864751Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the drain plug (A).
    Fig 8: Locating Drain Plug
    G04864752Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the filler plug (A).
    Fig 9: Locating Filler Plug
    G04864753Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the reverse idle bolt (A) from the transaxle case.
    Fig 10: Locating Reverse Idle Bolt
    G04864754Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the housing bolt (3EA) from the clutch housing inside.
    Fig 11: Locating Housing Bolts
    G04864755Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the transaxle case (A) from the housing (B). (Bolt: 11EA)
    Fig 12: Identifying Transaxle Case And Housing
    G04864756Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the differential outer race (A).
    Fig 13: Locating Differential Outer Race
    G04864757Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the output outer race (A).
    Fig 14: Locating Output Outer Race
    G04864758Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the input shaft oil guide (A) in the transaxle case.
    Fig 15: Locating Input Shaft Oil Guide
    G04864759Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the oil guide (A).
    Fig 16: Locating Oil Guide
    G04864760Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the bushing (A) (3EA).
    Fig 17: Locating Bushings
    G04864761Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the drive shaft oil seal (A).
    Fig 18: Locating Drive Shaft Oil Seal
    G04864762Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the reverse idle gear assembly (A).
    Fig 19: Locating Reverse Idle Gear Assembly
    G04864763Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove the reverse shaft lever assembly (A). (Bolt: 2EA)
    Fig 20: Locating Reverse Shaft Lever Assembly
    G04864764Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the spring pin.
    NOTE: Be careful not to damage it when removing spring pin.
    Fig 21: Removing/Installing Spring Pin
    G04864765Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the shift rail and fork assembly.
    Fig 22: Identifying Shift Rail And Fork Assembly
    G04864766Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the bearing retainer (A). (Bolt: 4EA)
    Fig 23: Locating Bearing Retainer
    G04864767Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the input shaft (A) and output shaft (B) assembly together from the clutch housing.
    Fig 24: Locating Input Shaft And Output Shaft
    G04864768Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the differential assembly (A).
    Fig 25: Locating Differential Assembly
    G04864769Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the differential oil seal (A).
    Fig 26: Locating Differential Oil Seal
    G04864770Courtesy of KIA MOTORS AMERICA, INC.
  28. Remove the clutch release lever fulcrum bolt (A).
    Fig 27: Locating Clutch Release Lever Fulcrum Bolt
    G04864771Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the differential outer race (A).
    Fig 28: Locating Differential Outer Race
    G04864772Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the output shaft outer race (A).
    Fig 29: Locating Output Shaft Outer Race
    G04864773Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the magnetic (A).
    Fig 30: Locating Magnetic
    G04864774Courtesy of KIA MOTORS AMERICA, INC.
  32. Remove the output shaft oil guide (A).
    Fig 31: Locating Output Shaft Oil Guide
    G04864775Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the dowel pin (3EA).
    Fig 32: Identifying Dowel Pin
    G04864776Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the input shaft front oil seal (A).
    Fig 33: Locating Input Shaft Front Oil Seal
    G04864777Courtesy of KIA MOTORS AMERICA, INC.
  35. Remove the bushing (3EA) from the clutch housing.
    Fig 34: Identifying Bushing
    G04864778Courtesy of KIA MOTORS AMERICA, INC.