Transfer Case: Other Kia Sorento I facelift

COMPANION FLANGE

Note. Position transfer case on work bench with rear or cover side up. Use wooden blocks under front to keep assembly level.

1. Remove nut and washer.
2. Pull companion flange.
3. Remove oil seal.
4. If installed, remove two plugs from cover.

Scheme 73

EXTERNAL ELECTRIC SHIFT

On electric shift units, remove components as follows.

1. Remove bolt (1).
2. Remove three bolts (3).
3. Remove sensor and harness bracket.
4. Remove speed sensor assembly.
5. Remove motor assembly.

LOCK SHIFT

1. From electric shift only, remove retaining ring and slide clutch housing from shift collar hub.
2. Remove shift collar hub from output shaft.
3. Together, slide 2W-4W lockup assembly and lockup fork from output shaft and rail shaft. Separate assemblies and remove rail shaft.
4. To disassemble 2W-4W lockup assembly, remove snap ring, lockup hub and return spring from lockup collar. NOTE: One-piece, plastic lockup fork replaces earlier fork assembly with metal fork and separate roller parts.

Scheme 74

CHAIN DRIVE

1. Remove snap ring and spacer from output shaft (front).
2. Together, slide drive sprocket, driven sprocket and drive chain from output shafts (rear and front). Separate sprockets and chain when out of assembly.

Scheme 75

OIL PUMP

1. Remove four bolts (2) and retainer. Slide rear pump cover off output shaft.
2. Loosen hose clamp and separate hose coupling from pump housing. Slide pump housing off output shaft.
3. Remove hose clamp, hose coupling and strainer.
4. Remove two pump pins and spring from output shaft.
5. Slide front pump cover off output shaft and remove output shaft.

Scheme 76

FRONT OUTPUT SHAFT

1. Hold yoke and remove nut and washer. Pull yoke assembly and oil seal.
2. Press deflector from yoke only if replacement is required.
3. Remove output shaft.

Scheme 77

ADAPTER, INPUT SHAFT AND GEAR CARRIER

1. Remove breather.
2. Remove six bolts (2). Carefully pry front adapter up to break sealant band with transfer case. Use care not to damage adapter or case.
3. Remove adapter assembly, input shaft assembly and gear carrier assembly as an assembled group.
4. Holding end of input shaft on workbench, press down on adapter while expanding long ends of snap ring.
5. Remove snap ring and pump oil seal from front adapter. Remove pin only if replacement is required
6. Remove retaining ring (8). Pull bearing and thrust washer from end of input shaft assembly. Remove input shaft assembly from gear carrier assembly.
7. To disassemble input shaft assembly, pull sleeve bearing and needle bearing from input shaft.
8. Remove retaining ring (16) and thrust plate end sun gear from planet carrier assembly.

Scheme 78

SHIFT CAM (ELECTRIC PARTS)

1. Remove electric shift cam group (1-4) from transfer case as an assembly.
2. Slide electric shift cam off shift shaft.
3. Clamp retainer end of shift shaft.
4. Keeping fingers away from spring ends, pry torsion spring out of engagement with shaft drive tang using a screwdriver.
5. Remove torsion spring and spacer from shift shaft.

Scheme 79

1. If removed, press deflector onto yoke.
2. Position output shaft in transfer case and install yoke assembly, oil seal, washer and nut.
3. Hold yoke and torque nut to 150-180 lb-ft (203-244 N.m).

Scheme 80

1. On work bench, next to transfer case assembly, position driven sprocket (with internal spline) at front output shaft end of case and drive sprocket (with smooth bore) at output shaft end.
2. Assemble drive chain around sprockets.
3. Grasp each sprocket, hold drive chain tight and parallel with transfer case, and install chain drive assembly over output shaft. It may be necessary to rotate driven sprocket slightly to engage splines on front output shaft.
4. Install spacer on front output shaft. Install snap ring in shaft groove over spacer.

Scheme 81

LOCKUP SHIFT

1. Assemble return spring and lockup hub in lockup collar and retain with snap ring, completing 2W-4W lockup assembly.
2. Install rail shaft in transfer case, through reduction shift fork assembly previously installed and into blind hole in case.
3. Engage lockup fork in groove in 2W-4W lockup assembly and slide this group down over output shaft and rail shaft.
4. Install shift collar hub, engaging splines on output shaft and in 2W-4W lockup assembly.
5. On electric shift units only, install electric shift cam group previously assembled and clutch housing as follow: Position electric shift cam group rotated so that end of torsion spring will contact side of reduction shift fork assembly that faces up, toward top of case. Holding rail shaft down, raise up fork assemblies slightly. Rotate electric shift cam group into position so that roller on reduction shift fork assembly is in groove in shift cam and button on lockup fork is on cam end. Then lower this group of parts into the transfer case engaging shift shaft on pin in transfer case. Position clutch housing in transfer case over shift collar hub. Attach with retaining ring in clutch collar hub groove.

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1. Position cover on bed of suitable press so that open face of cover is up and parallel with press bed.
2. Position end of needle bearing with identification marking up and press into cover until upper end of bearing is 1.593 -1.603 in. (40.47 -40.97 mm) below face of cover that mates with transfer case.
3. Press in ball bearing to bottom in cover and install snap ring.
4. On electric shift units only, install parts as follow: Verify that four O-rings (one on wire and one each on three studs) are in place on clutch coil assembly. Install clutch coil assembly in inside of cover, with electrical wire and studs extending through cover. Use care not to kink or trap electrical wire under clutch coil assembly. Attach with three nuts and torque to 6-8 lb-ft (8-11 N.m). Install motor bearing and oil seal in cover.
5. On all units, install return spring over rail shaft in transfer case to rest on shift fork.
6. Install magnet in slot in transfer case.
7. Apply continuous 1/16 in. (1.6 mm) bead of sealant (Neutral Cure RTV, Loctite 598) all around transfer case mounting surface for cover assembly. Center sealant bead between edges of surface. Circle bolt holes. Remove excess if sealant bead is larger than 1/16 in. (1.6 mm).
8. Install cover assembly on transfer case. All of the following alignment conditions must be met for the cover assembly to seat on transfer case properly. Cover holes with transfer case dowel pins. Cover bearings with output shafts. Blind hole in cover with rail shaft. Make sure spring in not cocked. On electric shift, check with pen light through cover hole for speed sensor. On electric shift units, cover bearing with shift shaft.
9. Install nine bolts positioning identification tag and wiring clip under bolt heads at locations. Torque bolts to 20-34 lb-ft (27-46 N.m).
10. Install speedo gear over spline of output shaft into cover assembly.
11. Press new oil seal into cover assembly.

Scheme 87

1. Position motor assembly so that triangular slot in motor will align with shift shaft. Move motor in to engage shift shaft and contact cover. Then rotate motor in clockwise direction until motor is in correct position and mounting holes are aligned.
2. Fit O-ring on speed sensor and install speed sensor assembly in cover. Install bracket so that it is over speed sensor and install three bolts. Torque bolts to 6-8 lb-ft (8-11 N.m).
3. Install bolt and washer at bracket end of motor assembly and torque to 6-8 lb-ft (8-11 N.m).

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1. Remove the transfer case from the vehicle.
2. Remove the flange washer and nut.
3. Disconnect the shift motor/clutch coil connector and the speed sensor connector.
4. Remove the outer tube of the speed sensor connector wire.
5. Remove the wire fixing cap in the rear of the speed sensor connector.
6. Disconnect the speed sensor connector.
7. Remove the shift motor.
8. If necessary, remove the front and rear speed sensors.
9. Remove the mounting bolts for the rear and front case.
10. Make sure that the front case is facing downward so that the rear cover is facing upwards.
11. Separate the front case from the rear case.
12. Remove all traces of gasket sealant from the mating surfaces of the front case and rear case.
13. If the speedometer drive gear is to be replaced, first remove the flange seal or use the Impact Slide Hammer to pop off the flange seal. CAUTION: Do not damage the bearing and the bearing case.
14. Remove the speedometer drive gear and upper tone wheel.
15. If the rear output shaft bearing requires replacing, remove the internal snap ring that retains the bearing in the bore.
16. From the outside of the case, drive out the bearing.
17. Remove the three nuts and washers retaining the clutch coil assembly to the rear case.
18. Pull the coil assembly, along with the O-rings and wire, from the case.
19. Remove the bearing assembly from the output shaft.
20. Remove the clutch housing from the output shaft.
21. Remove the balls and the apply cam and the wave spring from the output shaft.
22. Remove the snap ring from the output shaft.
23. Remove the clutch pack and lower tone wheel from output shaft.
24. Remove the chain, the driven sprocket and the drive sprocket as an assembly.
25. Remove the thrust washer from the output shaft.
26. Remove the oil pan magnet from the slot in the front of the case bottom.
27. Remove the output shaft and oil pump as an assembly.
28. If required, to remove the pump from the output shaft, rotate the pump to align.
29. Pull out the shift rail.
30. Remove the helical cam from the front case.
31. If required, remove the helical cam, torsion spring and sleeve from the shaft.
32. Remove the high-low range shift fork and collar as an assembly.
33. Expand the tangs of the large snap ring in the case using the ring pliers or equivalent.
34. With the input shaft against a bench, push the case down and slide the main drive gear bearing retainer off the bearing.
35. Lift the input shaft and front planet from the case.
36. If required, remove the oil seal from the case by prying and pulling on the curved-up lip of the oil seal or use the slide hammer to pop off the oil seal.
37. Remove the internal snap ring from the planetary carrier.
38. Separate the front planet from the input shaft.
39. Remove the external snap ring from the input shaft.
40. Place the input shaft in a vise and remove the bearing.
41. Remove the thrust washer, thrust plate and the sun gear off the input shaft.
42. Inspect the bushing and needle bearing in the end of the input shaft for wear or damage. CAUTION: Under normal use, the needle bearing and bushing should not require replacement. If replacement is required, the bushing and needle bearing must be replaced as a set.
43. If required, remove the front yoke to flange seal by prying and pulling on the curved-up lip of the yoke to flange seal.
44. If required, remove the internal snap ring retaining the front output shaft ball bearing and remove the bearing.

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1. Before assembly, lubricate all parts with the specified grease oil.
2. If removed, drive the bearing into the front output case bore.
3. Install the internal snap ring that retains the bearing to the front case.
4. If removed, install the front yoke to flange seal in the front case bore.
5. If removed, install the yoke to flange seal into the mounting adapter bore.
6. If the input shaft needle bearing and bushing were removed, install a new bearing and bushing.
7. The recessed face of the sun gear and the snap ring groove on the bearing outer race should be toward the rear of the transfer case.
8. The stepped face of the thrust washer should face toward the bearing.
9. Slide the sun gear, thrust plate and thrust washer into position on the input shaft.
10. Press the bearing over the input shaft.
11. Install the external snap ring to the input shaft.
12. Install the front planet to the sun gear and input shaft.
13. Install the internal snap ring to the planetary carrier.
14. Place the tanged snap ring in the case. Expand the snap ring with the snap ring pliers and install the planetary carrier assembly.
15. Check the installation by holding the case and carefully tapping the face of the input shaft against a wooden block to make sure the snap ring is installed.
16. Remove all traces of gasket sealant from the front case and mounting adapter mating surfaces.
17. Install the high-low shift fork and high-low collar as an assembly into the front planet.
18. Check the pump to make sure the pump rotates freely.
19. Inspect the outside surfaces and bore of the oil pump.
20. Install the output shaft and oil pump in the input shaft. Make sure that the internal splines of the output shaft engage the internal splines of the high-low shift collar. Make sure that the oil pump retainer arm and oil filter leg are in the groove and slot of the front case.
21. Install the oil pan magnet in the slot in the front case just above the oil filter leg.
22. Install the front output shaft in the front case.
23. Install the thrust washer on the rear output shaft.
24. Install the chain, drive sprocket and driven sprocket as an assembly over the output shaft. CAUTION: The driven sprocket (on the front output shaft) must be installed with the marking REAR facing toward the rear case, if so marked.
25. Install tone wheel onto the front output shaft. Make sure the spline on the tone wheel engages the spline on the front output shaft.
26. Install clutch pack assembly onto the rear output shaft. Make sure that the spline on the clutch pack engages to the spline of the sprocket.
27. Install snap ring onto the rear output shaft. Start the snap ring over the spline and use the wave spring to seat the snap ring in the snap ring groove. If the snap ring will not install, the thrust washer inside the clutch pack may not be seated properly.
28. Three slots on the thrust washer must be aligned with the three tabs on the clutch pack housing.
29. Install the apply cam onto the rear output shaft.
30. Install three balls into the apply cam.
31. Install cam and coil housing assembly onto rear output shaft.
32. Install thrust bearing assembly onto output shaft.
33. Install the clutch coil from inside the rear case until the wire and studs extend through the cover.
34. Install the washers and nuts and tighten to 8-11 N.m.
35. Slide the spring spacer on the cam shaft and position it beneath the drive tang.
36. Place the torsion spring on the cam shaft. Position the first spring tang to the left of the cam shaft drive tang.
37. Wind the second spring tang clockwise past the drive tang.
38. Push the torsion spring and sleeve in as far as it will go.
39. Install the helical cam and slide the drive tang between the torsion spring tangs as far as it will go.
40. Install the pin on the tang end of the helical cam into the hole in the front case. Position the torsion spring tangs so that they are pointing toward the top side of the transfer case and just touching the high-low shift fork. CAUTION: Do not bend the helical cam during installation to the front case because of possible damage to the pin at the tang end of the motor shaft.
41. Install the shift rail through the high-low shift fork and make sure that the reverse gear shift rail is seated in the front case bore.
42. Install upper and lower speed sensors into the cover. Feed the coil wire through the upper speed sensor wire shield.
43. Install upper tone wheel, speedometer gear and rear output seal.
44. Coat the mating surface of the front case with sealant.
45. The following procedure must be followed prior to installing the rear case onto the front case half: Align the output shaft with the rear case output shaft bore. Align the helical cam with the rear case motor bore. If difficulty is encountered with seating the rear case, tap the rear output shaft with a sharp blow using a rubber mallet in a direction away from the triangular shaft while pushing down on the rear case.
46. Install the bolts retaining the case halves and tighten to 25-37 N.m (250-370 kg-cm, 19-25 lb-ft).
47. Install shift shaft oil seal if it is not installed.
48. Using pliers equipped with soft jaws, rotate the triangular shaft so it is aligned with the triangular slot in the transfer case shift motor. If triangular shaft will not rotate, rotate the rear output shaft.
49. Slightly loosen the two nuts that attach the slotted support bracket to the end of the motor house.
50. Apply the sealant to motor housing base and install on transfer case.
51. Install the transfer case shift motor.
52. Holding the slotted support bracket tight against the motor housing end, secure the bracket to the transfer case, tightening the bolt with lock washer to 8-11 N.m (80-110 kg. cm, 6-8 lb. ft).
53. Retighten the two nuts that attach the slotted support bracket to the end of the motor to 3-4 N.m (30-40 kg. cm, 2-3 lb. ft).