Removal & Installation - A/t: Application Kia Optima I

APPLICATION

Note. For information relating to Spectra models, refer to Sephia unless otherwise directed.

AUTOMATIC TRANSAXLE/TRANSMISSION APPLICATIONS

Note. For manual transmission removal procedure, see appropriate article in CLUTCHES.

1. Disconnect negative battery cable. Raise and support vehicle. Drain transaxle. Remove wheels and splash shields. Disconnect air hose, and remove air cleaner and resonance chamber. Disconnect Vehicle Speed Sensor (VSS) electrical connectors from transaxle.
2. Disconnect Transaxle Range (TR) switch connector, solenoid valve electrical connectors and transmission oil temperature sensor. Disconnect automatic transaxle cooler hoses. Plug hoses to prevent contamination of oil cooler lines. Attach support frame to engine.
3. Disconnect lower control arm to steering knuckle ball joints. Separate lower control arm from steering knuckle. Disconnect left and right side tie rod ends from knuckles. Remove stabilizer bar. Separate left drive axle from engine. On 2.5L models, Separate right drive axle from center bearing support bracket. Remove center bearing support bracket to engine mounting bolts. Remove intermediate shaft and center bearing support bracket from transaxle. On 2.4L models, separate right drive axle from transaxle.
4. Remove gearbox "U" joint bolt and return tube mounting bolts. Remove front exhaust pipe to manifold bolts, then lower front exhaust pipe. Remove transaxle mounting bolt, then remove transaxle support bracket.
5. Drain power steering fluid. Disconnect steering columns to steering rack universal joint pinch bolt. Disconnect power steering supply and return lines from power steering rack. Support subframe. Remove 6 subframe mounting bolts, then lower subframe from vehicle.
6. Remove starter motor. Support transaxle with jack. Disconnect torque converter to drive plate bolts. Remove engine to transaxle bolts. Lower transaxle from vehicle.

1. To install transaxle, reverse removal procedure. Install control cable with TR switch and gear shift selector lever in "N" position. Ensure all free play is removed from cable.
2. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-123311-S39201864202001091900000) . Install NEW clips onto axle shaft ends before installing axle shafts. For more information on axle shafts. See appropriate article in FWD AXLE SHAFTS article in DRIVE AXLES DRIVE AXLES. Fill transaxle and power steering system with required amount of fluid, and check for external leaks.

1. Disconnect negative battery cable. Raise and support vehicle. Remove wheels, then remove splash shields. Remove fresh air duct. Disconnect turbine speed sensor, solenoid and Transaxle Range (TR) switch.
2. Remove engine ground strap. Disconnect Vehicle Speed Sensor (VSS), then disconnect shift linkage from transaxle. Disconnect crankshaft position and oxygen sensors. Disconnect ATF cooler lines from transaxle, plug lines to prevent system contamination.
3. Remove upper transmission mounting bolts. Attach Support Bracket (0K201 170 AA0A) to engine. Remove catalytic converter to exhaust manifold nuts, then lower exhaust pipe.
4. Remove torque converter housing access cover. Remove torque converter to drive plate mounting bolts, rotate engine at crankshaft as necessary to access bolts. Remove engine pan to transaxle mounting bolts.
5. Disconnect left tie rod from steering knuckle. Disconnect left tension rod from steering knuckle. Disconnect left lower control arm ball joint from steering knuckle.
6. Remove engine mounting to member chassis bolts and nuts, them remove engine mounting member. Remove stabilizer bar and control link. Gently pry left drive shaft from transaxle. Install Idle Gear Support (0K201 270 014) into transaxle. Remove right drive axle from transaxle.
7. Support transaxle with jack, then remove transaxle mount. Remove remaining engine to transaxle mounting bolts, then lower transaxle from vehicle.

To complete installation, reverse removal procedure. Tighten fasteners to specifications. See TORQUE SPECIFICATIONS . Fill transmission with required amount of fluid, and check for leaks.