Automatic Transaxle Diagnosis & Overhaul: Overhaul Kia Optima I

DISASSEMBLY

1. Remove the torque converter and set aside.
2. Measure the input shaft end play.
3. Remove the left and right roll stopper brackets.
4. Remove the wiring harness bracket.
5. Remove the control cable support bracket.
6. Remove the dipstick.
7. Remove the oil cooler feed tube, gasket, and eye bolt.
8. Remove the input shaft speed sensor and the output shaft speed sensor.
9. Remove the manual control lever, then remove the transaxle range switch.
10. Remove the vehicle speed sensor.
11. Remove the valve body cover.
12. Remove the manual control shaft detent.
13. Disconnect the harness connectors of the valve body. CAUTION: To prevent damage to transaxle components make sure that the manual control lever and the park/neutral switch have been removed before attempting to remove the valve body. NOTE: The valve body mounting bolts are different lengths. Note the locations of the bolts to aid in assembly.
14. Remove 28 of the valve body mounting bolts. Do not remove the bolts shown in the illustration at this time.
15. Remove the oil temperature sensor.
16. Remove the valve body, gasket, and the 2 steel balls. NOTE: Make sure not to lose the 2 steel balls.
17. Remove the solenoid valve wiring harness snap ring.
18. Remove the solenoid valve harness.
19. Remove the strainer.
20. Remove the second brake retainer oil seal. CAUTION: The second brake retainer oil seal must be removed before removing the transaxle powertrain components from the case or damage to the seal will occur.
21. Remove the 4 accumulator pistons, the 4 large springs, and the 3 small springs.
22. Remove the manual control lever shaft pin (roller).
23. Remove the manual control lever shaft.
24. Remove the parking pawl rod.
25. Remove the torque converter housing and 18 mounting bolts. Tap the housing off with a non-metallic hammer.
26. Remove the 2 O-rings from the case.
27. Remove the differential.
28. Remove the main oil filter.
29. Remove oil pump mounting bolts. CAUTION: The oil pump is not serviceable, it must be replaced as a pump assembly. Do not disassemble the pump as improper alignment during assembly will cause pump failure and could cause damage to the transaxle.
30. Install the special tool (09452-33100), as shown in the illustration.
31. Remove the oil pump by turning special tool screws clockwise.
32. Remove the oil pump gasket.
33. Remove thrust bearing #1.
34. Grasp the input shaft, then pull out the underdrive clutch and input shaft as an assembly.
35. Remove thrust bearing #2.
36. Remove the underdrive clutch hub.
37. Remove the rear cover and mounting bolts.
38. Remove the thrust race #8.
39. Remove the 4 seal rings. NOTE: Do not remove the input shaft rear bearing unless it is defective. Once this bearing has been removed, it MUST be replaced.
40. Remove the 3 O-rings.
41. Remove thrust bearing #7.
42. Remove the reverse and overdrive clutch.
43. Remove thrust bearing #6.
44. Remove the overdrive clutch hub.
45. Remove thrust bearing #5.
46. Remove the planetary reverse sun gear.
47. Remove the second brake piston snap ring.
48. Remove the second brake piston and return spring.
49. Remove the second brake pressure plate, 3 brake discs, and 2 brake plates.
50. Remove the overdrive planetary carrier.
51. Remove thrust bearing #4.
52. Remove the output planetary carrier.
53. Remove the underdrive sun gear.
54. Remove thrust bearing #3.
55. Remove the low/reverse reaction plate snap ring.
56. Remove the low/reverse reaction plate and brake disc.
57. Remove the low/reverse brake snap ring.
58. Remove the low/reverse 6 brake discs, 5 brake plates, and brake pressure plate.
59. Remove the wave spring.
60. Remove the parking pawl shaft.
61. Remove the spacer.
62. Remove the parking pawl spring. Note the orientation of the spring to aid in reassembly.
63. Remove the 2 parking roller support shafts.
64. Remove the parking pawl case.
65. Remove the parking roller support.
66. Remove the snap ring.
67. Remove the spring retainer.
68. Remove the return spring.
69. Remove the low/reverse brake piston. Use compressed air directed into the valve body passage.
70. Remove the 7 transfer gear mounting bolts.
71. Remove the transfer drive gear.
72. Remove the plastic cap, if present.
73. Straighten the locking tab of the output shaft lock nut, if bent. NOTE: The output shaft lock nut is left-hand thread.
74. Remove the output shaft lock nut.
75. Remove the output shaft bearing retainer mounting bolts.
76. Tap out the output shaft, tapered roller bearing, and the collar from the back side.
77. Tap out the bearing outer race and spacer using a suitable driver.
78. Remove the snap ring.
79. Remove the differential bearing outer race and spacer from the torque converter housing.
80. Remove the differential bearing outer race from the transaxle case.

REASSEMBLY

1. Tap the differential bearing outer race into the transaxle case using special tools (09500-11000 and 09532-11500).
2. Tap the output shaft bearing outer race into the transaxle case using special tool (09500-11000).
3. Install the spacer and the snap ring.
4. Install the low-reverse brake piston, return spring, and spring retainer.
5. Install the snap ring using special tools (09453-21000). To be sure that you have the correct snap ring, measure the thickness and compare it to the chart in the service manual.
6. Install the wave spring. NOTE: In steps 7 through 9 , you will determine the actual clearance between the low-reverse brake discs and plates when the clutch is released.
7. Replace the pressure plate of the low-reverse brake, then install the brake discs, 5 brake plates and the snap ring.
8. Install the low and reverse reaction plate and the old snap ring.
9. With a dial indicator installed, move the special tool up and down to measure the end play. Standard Value: 0-0.16 mm (0-0.0063 in.) If the end play is incorrect, measure the old snap ring, then select the proper snap ring, using snap ring and spacer adjustment charts, and recheck the clearance. See «SNAP RING & SPACER ADJUSTMENT»(ref-178330-S41217935422005061400000) .
10. Remove the special tool. NOTE: In steps 11 through 16 , you will determine the actual clearance between the second brake discs and plates when the clutch is released.
11. Install the 3 second brake discs and 2 plates.
12. Install the second brake return spring, second brake piston, and snap ring.
13. Install a dial indicator as shown in the illustration.
14. Move up and down, while observing the end play.
15. To determine the proper thickness of the second brake pressure plate. Standard Value: 0.79-1.25 mm (0.0311-0.0492 in.)
16. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart in the service manual and recheck the clearance. NOTE: In steps 18 through 21 , you will determine the actual clearance between the low-reverse brake discs and plates when the clutch is released.
17. Install the special tool in place of the low/reverse brake pressure plate.
18. Install the 6 brake discs, 5 brake plates and snap ring.
19. Turn the transaxle upside down, install a dial indicator, as shown in the illustration.
20. Move the special tool up and down while observing the end play.
21. To determine the proper thickness of the low/reverse brake pressure plate. Standard Value: 1.65-2.11 mm (0.0650-0.0830 in.)
22. If the standard value is incorrect, select a pressure plate of the proper thickness, using snap ring and spacer adjustment charts, and recheck the clearance. See «SNAP RING & SPACER ADJUSTMENT»(ref-178330-S41217935422005061400000) .
23. Remove the special tool.
24. Install the output shaft.
25. Install the output bearing retainer mounting bolts. Tighten the bolts to 23 Nm (17 lbs. ft) of torque.
26. Install the output shaft collar and tapered roller bearing using special tool (09455-33200). NOTE: The output shaft lock nut is left-hand thread.
27. Apply ATF and install the old lock nut and tighten to 167 Nm (123 lbs. ft). Loosen the nut 1 full turn, then retighten to specifications. Do not stake the lock nut unless instructed to do so by the instructor.
28. Install a dial indicator as shown in the illustration.
29. Move the output shaft in and out to measure the end play. Standard Value: 0.01-0.09 mm (0.0004-0.0035 in.)
30. If the standard value is incorrect, use this formula to select the correct spacer using snap ring and spacer adjustment charts. See «SNAP RING & SPACER ADJUSTMENT»(ref-178330-S41217935422005061400000) .
31. Install the output shaft protective cap.
32. Install the transfer drive gear using special tool (09500-11000).
33. Install the 7 transfer gear mounting bolts. Tighten the bolts to 19 Nm (14 lbs. ft).
34. Install the parking pawl, spacer and spring, then install the parking pawl shaft.
35. Install the parking roller support, then the two parking roller support shafts. CAUTION: Be sure to install the thrust bearing in the proper direction.
36. Install the underdrive sun gear and thrust bearing #3 to the output planetary carrier. CAUTION: Be sure to install the thrust bearing in the proper direction.
37. Install the output planetary carrier and thrust bearing #4.
38. Install the overdrive planetary carrier. NOTE: Rotating the output shaft will help align the clutch teeth and help the carrier seat.
39. Install the reverse planetary sun gear.
40. Install the wave spring.
41. Install the low/reverse pressure plate, 6 brake discs, and 5 brake plates.
42. Install the snap ring.
43. Install the reaction plate.
44. Install the snap ring.
45. Install the second brake pressure plate, 3 brake discs, and 2 brake plates.
46. Install the return spring and second brake piston.
47. Install the snap ring. CAUTION: Be sure to install the thrust bearing in the proper direction.
48. Install thrust bearing #5. CAUTION: Be sure to install the thrust bearing in the proper direction.
49. Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch. CAUTION: Be sure to install the thrust bearing in the proper direction.
50. Install the reverse and overdrive clutch and thrust bearing #7.
51. Install the three O-rings.
52. Install the 3 seal rings into the rear cover. NOTE: The cover should be clean and dry for step 56 . It is only being installed to measure the underdrive sun gear end play.
53. Install the used thrust race #8 and rear cover.
54. Using a dial indicator, measure the end play of the underdrive sun gear. Standard Value: 0.25-0.45 mm (0.0098-0.0177 in.)
55. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper size using snap ring and spacer adjustment charts. See «SNAP RING & SPACER ADJUSTMENT»(ref-178330-S41217935422005061400000) .
56. Reinstall the rear cover and mounting bolts. Tighten the mounting bolts to 23 Nm (17 lbs. ft).
57. Install the underdrive clutch hub. CAUTION: Be sure to install the thrust bearing in the proper direction.
58. Install thrust bearing #2.
59. Grasp the input shaft and lower the underdrive clutch into position. NOTE: Looking into the hole where the input speed sensor mounts to the case will help you ensure that the underdrive clutch is fully seated.
60. Install the used thrust bearing #1. CAUTION: Be sure to use a new oil pump gasket.
61. Install the oil pump, a new gasket, and the oil pump mounting bolts.
62. Using a dial indicator, measure the end play of the input shaft. Standard Value: 0.70-1.45 mm (0.0276-0.0371 in.)
63. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper size using snap ring and spacer adjustment charts. See «SNAP RING & SPACER ADJUSTMENT»(ref-178330-S41217935422005061400000) .
64. Reinstall the oil pump and mounting bolts. Tighten the mounting bolts to 23 Nm (17 lbs. ft).
65. Install the oil internal filter.
66. Install the differential.
67. Place two strips of solder, approximately 10 mm (0.39 in) long and 3 mm (0.12 in) thick, on the torque converter housing.
68. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 lbs. ft) of torque.
69. Remove the torque converter housing, the bolts and the solder.
70. Using a micrometer, measure the thickness of the pressed solder.
71. Select a spacer that will give the following clearance. Standard Value: 0.045 mm (0.0018 in.)-0.105 mm (0.0041 in.)
72. Install the differential spacer selected in the previous step in the torque converter housing.
73. Use special tools 09532-11500 and 09500-11000 to press in the differential bearing outer race.
74. Install the two O-rings.
75. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 lbs. ft) of torque.
76. Install the manual control lever shaft and parking pawl.
77. Install the manual control shaft roller.
78. Install the three small springs and three larger springs into the accumulator pistons. The accumulator springs are identified in the illustrations.
79. Install the accumulators with the springs according to the illustrations. The accumulators should be flush with the transaxle case.
80. Install the strainer and the second brake retainer oil seal. NOTE: Note the oil seal orientation in the illustration.
81. Install the solenoid wiring harness, then install the snap ring in its groove.
82. Install the valve body, gasket, and two steel balls.
83. Install the oil temperature sensor. Tighten the mounting bolt to 11 Nm (8 lbs. ft.).
84. Install 28 valve body mounting bolts. Tighten all valve body mounting bolts to 11 Nm (8 lbs. ft.).
85. Connect the solenoid wiring and temperature sensor connectors according to the illustration and the chart below.
86. Install the manual control shaft detent. Tighten the nut to 6 Nm (4.4 lbs. ft) of torque.
87. Install the valve body cover and mounting bolts. Tighten the mounting bolts to 9 Nm of torque.
88. Install the vehicle speed sensor and mounting bolt. Tighten the mounting bolt to 5 Nm (3.7 lbs. ft.) of torque.
89. Install the park/neutral position switch. Tighten the mounting bolt to 11 Nm (8 lbs. ft) of torque.
90. Install the manual control lever. Tighten the mounting nut to 22 Nm (26 lbs. ft) of torque.
91. Install the input and output shaft speed sensors. Tighten the mounting bolts to 11 Nm (8 lbs. ft.) of torque. CAUTION: Make sure that you are installing the correct oil filter. While the engine oil filter and the transaxle oil filter lock similar, their filtering action is different. Installing the wrong oil filter could cause damage to the transaxle. Transaxle oil filters are identified as A/T ONLY.
92. Install the cooler feed tube with a new gasket and the eye bolt. Tighten the eye bolt to 30 Nm (22 lbs. ft) of torque.
93. Install the dipstick.
94. Install the control cable bracket. Tighten the mounting bolt to 23 Nm (17 lbs. ft).
95. Install the wiring harness bracket. Tighten the mounting bolt to 23 Nm (17 lbs. ft).
96. Install the two roll stopper brackets. Tighten the mounting bolts to 69 Nm (51 lbs. ft).
97. Install the torque convertor and secure it so that dimension A. Meets the reference value. Reference value : approx. 12.2 mm (0.480 in.) CAUTION: Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the oil pump seal.

1. Remove the transfer driven gear by press.
2. Remove the taper roller bearing.

1. Remove the input shaft snap ring.
2. Remove the input shaft.
3. Remove the 2 seal rings.
4. Remove the clutch reaction plate snap ring.
5. Remove the clutch reaction plate.
6. Remove the 4 clutch discs and 4 clutch plates.
7. Compress the clutch return springs using special tools, 09453-24000 and 09453-21000 then remove the clutch spring retainer snap ring.
8. Remove the clutch spring retainer.
9. Remove the D-ring seal.
10. Remove the clutch return spring.
11. Remove the underdrive clutch piston using compressed air.
12. Remove the 2 D-ring seals.

1. Install the 2 D-ring seals.
2. Install the underdrive clutch piston.
3. Install the clutch return spring.
4. Install the D-ring seal.
5. Install the clutch spring retainer.
6. Compress the clutch return springs using special tools, 09453-21100 and 09453-21000, then install the clutch spring retainer snap ring. CAUTION: Dip each clutch disc in ATF before assembling.
7. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outer circumference hole (B) in the underdrive clutch retainer.
8. Install the 4 clutch discs and the 4 clutch plates.
9. Install the clutch reaction plate with the shear droop toward the clutch disc.
10. Install the clutch reaction plate snap ring.
11. Install special tools, MD998924 and MB991628, as shown, then check the clearance between the snap ring and the reaction plate using a feeler gauge. Standard value : 1.6-1.8 mm
12. If the clearance is correct, measure the old snap ring, then select the correct size using snap ring and spacer adjustment charts. See «SNAP RING & SPACER ADJUSTMENT»(ref-178330-S41217935422005061400000) .
13. Install the seal rings.
14. Install the input shaft.
15. Install the input shaft snap ring.

1. Remove the overdrive clutch reaction plate snap ring.
2. Remove the overdrive clutch reaction plate.
3. Remove the 2 overdrive clutch discs and 2 plates.
4. Remove the reverse clutch reaction plate snap ring.
5. Remove the reverse clutch reaction plate.
6. Remove the 4 reverse clutch discs and 4 plates.
7. Compress the clutch return springs using special tools, 09453-21000 then remove the clutch spring retainer snap ring.
8. Remove the clutch spring retainer.
9. Remove the D-ring seal.
10. Remove the clutch return spring.
11. Remove the overdrive clutch piston using compressed air.
12. Remove the D-ring seal.
13. Remove the Reverse clutch piston.
14. Remove the 3 D-ring seals.

1. Install the 3 D-ring seals.
2. Align the outer circumference holes (A and B) on the reverse piston and the reverse piston retainer before assembly.
3. Install the Reverse clutch piston.
4. Install the D-ring seal.
5. Install the overdrive clutch piston.
6. Install the clutch return spring.
7. Install the D-ring seal.
8. Install the clutch spring retainer.
9. Compress the clutch return springs using special tools, 09453-21000 then install the clutch spring retainer snap ring.
10. Check the clearance between the snap ring and the return spring retainer Standard value : 0-0.09 mm (0-0.0035 in.)
11. If the clearance is incorrect, measure the old snap ring, then select the correct size from the chart in the service manual. CAUTION: Dip each clutch disc in ATF before assembling.
12. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outer circumference hole (B) in the reverse clutch retainer.
13. Install the 4 reverse clutch discs and 4 plates.
14. Install the reverse clutch reaction plate.
15. Install the reverse clutch reaction plate snap ring.
16. Install special tools, 09453-21000 as shown, then check the clearance between the snap ring and the reaction plate using a feeler gauge. Standard value : 1.6-1.8 mm (0.0630-0.0709 in.)
17. If the clearance is incorrect, measure the old snap ring, then select the correct size from the chart in the service manual. Dip each clutch disc in ATF before assembling.
18. Align the spaces between the teeth (A) on the clutch plates, clutch discs, and reaction plate to the outer circumference hole (B) in the overdrive clutch retainer.
19. Install the 2 overdrive clutch discs and 2 plates.
20. Install the overdrive clutch reaction plate.
21. Install the overdrive clutch reaction plate snap ring.
22. Check the clearance between the snap ring and the clutch reaction plate. Standard value : 1.5-1.7 mm (0.0590-0.0670 in.)
23. If the clearance is incorrect, measure the old snap ring, then select the correct size using snap ring and spacer adjustment charts. See «SNAP RING & SPACER ADJUSTMENT»(ref-178330-S41217935422005061400000) .

1. Loosen the lock nut caulking.
2. Remove the lock by using socket.

1. Apply ATF to the new lock nut and tighten to the specified torque. And loosen 1 turn and tighten to the specified torque again.
2. Caulk the lock nut by using punch.

1. Clamp the differential case in a vise.
2. Remove the differential drive retaining bolts and remove the differential drive gear from the case.
3. Remove the taper bearing using the special tool (09433-21000). CAUTION: Do not reuse the bearing removed from the shaft.
4. Drive out the lock pin from the hole A using a punch.
5. Drive out the pinion shaft.

1. Install the spacer on the back of the side gear and then install the gear in the differential case. CAUTION: When installing a new side gear, use a spacer of medium thickness [0.83-0.92 mm (0.33-0.036 in.)]. Do not reuse the lock pin. The lock pin head must be sunk below the flange surface of the differential case.
2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears by turning them.
3. Insert the pinion shaft.
4. Measure the backlash between the side gears and pinions. Standard value : 0.025-0.150 mm (0.001-0.006 in.) 0.025-0.0150 mm (0.001-0.006 in.)
5. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure. CAUTION: Adjust the backlash of both side gears to the same specification.
6. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin. CAUTION: Do not reuse the lock pin. The lock pin head must not protrude more than 3 mm (0.0118 in.) gear in the differential case.
7. Install the tapered roller bearing on both sides of the differential case using the special tool (09455-21100). CAUTION: When press-fitting the bearing, press on the inner race only.
8. Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the illustration. Specified sealant: BM stud locking No.2471 CAUTION: If a bolt is reused, remove the old sealant from the threads.