REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Sephia / Shuma (1995 release)

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Kia
	Sephia / Shuma
		Maintenance
		Engine
		Greasing system
		Cooling
		The power supply system and release
		Fuel system
		Ignition system
		Coupling
		Manual transmission
		Automatic Transmission
			Check of work and adjustment of position of the selector lever
			Check of level and liquid replacement in an automatic transmission
			The procedure for replacing the liquid in the converter of an automatic transmission
			Leaks of a liquid from an automatic transmission
			Replacement of oil sealing rings
			The unit control valves
			Radiator cooling automatic transmission fluid
			Removing and installing automatic transmission
			Repair of an automatic transmission
			Oil pump
			The body of the control valve
			The switch O / D
			Switch range gearbox
			The temperature sensor of an automatic transmission
			Speed sensor at the input / turbine
			Speed sensor
			Solenoid valves
			The linear solenoid valve
			Lever
			Repair of the selector lever
		Axes and power shafts
		Steering
		Wheels and tires
		Brakes
		Suspension
		Body
		The air conditioning system
		Electrical equipment

For the separation of the crankcase, use only plastic hammers.

Do not use rags at transmission dismantling: rags fibers can hammer fluid passages. Some of the details are similar to each other, therefore at dismantling arrange them in such a way so as not to confuse them. Remove the control valve and clean it completely, if the clutch or brake band scorched or worse quality of a liquid in an automatic transmission.

Cleaning

printable version

Repair of an automatic transmission

Automatic transmission

1 - torque converter;
2 - oil pump shaft;
3 - tube level indicator and oil filling;
4 - speed sensor inlet / turbine;
5 - the switch of a range of transmission;
6 - an arm of a cable of the selector;
7 - an arm;
8 - the crankshaft position sensor;

9 - speed sensor and speedometer drive gear;
10 - inlet pipe;
11 - outlet pipe;
12 - oil pan;
13 - a lining to (replace);
14 - the case of the valve block;
15 - oil pump

Automatic transmission

1 - a lock ring;
2 - clutch forward / reverse;
3 - Small sun gear and the clutch ?��1;
4 - brake bands 2nd / 4th gear;
5 - anchor desk and a pin;
6 - a lock ring;
7 - coupling ?��2 and planetary unit;

8 - the holder of the actuator;
9 - piston actuator;
10 - the piston rod;
11 - a lock ring;
12 - internal gear;
13 - clutch 3rd / 4th gear

Automatic transmission

1 - the turbine shaft;
2 - the output;
3 - a nut;
4 - washer;
5 - a plate;
6 - shaft;
7 - a bolt;

8 - the holder of the lever;
9 - the lever of parking;
10 - the locking lever;
11 - a returnable spring;
12 - bolts;
13 - support of the modulator;
14 - the gearbox housing

Automatic transmission

1 - differential;
2 - cylindrical pin (replace);
3 - the bearing housing;
4 - an intermediate gear;
5 - output gear;
6 - a cover of the bearing;

7 - outer bearing rings (replace);
8 - shim (substitute);
9 - an oil sealing ring to (replace);
10 - O-rings (replace);
11 - Carter converter

General recommendations

Dismantling of an automatic transmission spend in a place protected from dust, dirt in order to avoid transmission parts. At dismantling check the condition of details of a transmission for wear and damage.

PERFORMANCE ORDER

1. Before disassembly, clean the outer surface of the transmission a cleaner or solvent.

2. Clear the removed details solvent and dry with compressed air. Clean all channels and apertures the compressed air, and check that they have no barriers.

A warning

When cleaning parts with compressed air, wear goggles.
Be careful not to spill liquid when removing the torque converter.

Dismantling

PERFORMANCE ORDER

	1. Remove the torque converter housing of the transducer.
	2. Manually remove the oil pump shaft.
3. Remove the dipstick tube and the oil filling.
4. Remove the speed sensor on the input / turbine.
5. Remove the switch range gearbox.
6. Remove selector cable bracket.
7. Remove the bracket.
8. Remove the crankshaft position sensor.
9. Remove the speed sensor and speedometer drive gear.
10. Remove the inlet pipe.
11. Remove the outlet pipe.
	12. Collect the special adaptation OK130 990 007 with holder OK130 175 011A
A warning Do not tilt transmission in one direction in the process of dismantling, as it can suddenly tip over and cause injury.
A warning Before turning over the gearbox, remove the oil pan. This ensures that all debris and particles remain in the pan.
	13. Remove the nineteen bolts and remove oil pan: a. Explore all debris and particles are found in the sump, and a magnet to determine the condition of components of a transmission. The presence of wear particles testifies to deterioration of the clutch plate drive or brake bands. Steel particles on the magnet indicate deterioration of the bearings, gears or the drive plate. The presence of aluminum particles indicate deterioration of plugs or transmission housing; b. in the presence of large amounts of foreign substances and particles, replace the torque converter and carefully check each part of the transmission.
14. Remove the clip (one bolt).
	15. Remove the solenoid valves.
16. Remove the three screws and remove the strainer.
17. Remove the screws A, B and C, and remove the brackets. The length of the bolts (measured from the base of the head): A: 30 mm B: 50 mm C: 14 mm
	18. Remove the valve block controls.
19. Remove the shaft and the plate: - Loosen the nut, and pull the shaft; - Remove the nut, remove the washer and plate.
	20. Remove the bolt and remove the holder lever parking.
	21. Remove the two screws of the lever holder parking.
22. Remove the locking lever and return spring.
	23. Remove the caliper modulator.
	24. Remove the ten bolts and remove the oil pump.

25. Remove the clutch forward / reverse: a. Remove the retaining ring of the turbine shaft; b. lift assembly clutch forward / reverse lever and remove it from the gear box.
	26. Remove small sun gear and the clutch ?��1.
A warning Use a length of wire for attaching a brake tape so that it is not damaged when pulling.
	27. Remove the brake tape 2-4.
28. Remove the pin, thus support the anchor rack.
	29. Remove the rack anchor.
	30. Remove the servo drive: a. Squeeze the servo piston and remove the retaining ring; b. remove the holder of the servo piston and spring.

31. Remove the one-way clutch ?��2 and planetary assembly: a. Remove the retaining ring; b. Remove the one-way clutch ?��2 with the planetary assembly; c. Remove the friction plate.

32. Remove the internal gear: a. Remove the retaining ring; b. remove the internal gear of the outlet housing.

33. Remove the 3-4 clutch: a. Remove the sealing ring from the shaft of the turbine side transducer; b. output shaft of the turbine in order to remove the clutch unit 3-4; c. Remove the coupling from the turbine shaft 3-4.
	34. Remove the bolts (from the transducer - and eight bolts from the gearbox - seven screws) and remove the gearbox housing by hitting it with a plastic hammer.
	35. Remove the output from the output gear.
	36. Remove the differential.
	37. Remove the bearings: a. round knockout hammer and beat out a cylindrical pin; b. remove the eleven bolts bearing housings; c. Remove the bearing by hitting it with a plastic hammer.
	38. Remove the idler gear and the output node, knocking them from the torque converter.

39. Remove the bearings: a. remove the bearing cap bolts; b. special adaptation OK130 175 011A remove the transmitter housing; c. squeeze bearing cover of the transmitter housing.
A warning Install previously removed the outer ring of the bearing during reassembly to adjust the bearing preload.
	40. Special adaptation OK130 170 012 remove the bearing outer race.

Assembly

A warning

If the plate drive or brake tape is replaced by a new, pre-installation of a new item soak in the liquid for an automatic transmission for at least two hours.

Before assembly, lubricate the fluid for automatic transmission all oil seals, rotating parts, O-rings and moving parts.

All O-rings, oil seals and gaskets must be replaced.

When reassembling, use petroleum jelly, but do not grease the.

When you need to replace the plug, replace the item (node) contains the same hub.

After applying sealant assembly must be made within 10 minutes and let stand 30 minutes before filling liquid for an automatic transmission.

PERFORMANCE ORDER

1. Align the cover bearing the guide bolts and press it as shown in the figure.

The inhaling moment: 10,8-13,7 N ??? m

2. Tapping with a plastic hammer, install the assembly intermediate gear and output gear.

3. Install bearing housing:
a. Install the bearing housing on the housing converter;
b. Align the groove on the intermediate shaft with the mark on the bearing housing;
c. a hammer and a thin knockout install cylindrical pin;
d. Eleven screw bolts.

Torque: 19-25 N ??? m

4. Set the parking stopper:
a. Install the parking lock and the shaft;
b. Install the spring and the retaining ring.
c. Manually move the shaft and make sure the parking stop working.

5. Establish a support modulator and fix new bolts.

Torque: 15-17 N ??? m

6. Set the release lever and return spring.

7. Set the parking lever.

8. Attach the lever and bolt.

The inhaling moment: 7,9-10,7 N ??? m

9. Install the plate and shaft:
a. Set plate washer and nut;
b. Tighten the nuts to torque.

Torque: 42-54 N ??? m

10. Install the differential into the housing of the converter. Establish special adaptation OK201 270 014.

11. Establish a new oil sealing ring on the block output gear.

12. Establish the case of the output to the output gear and install the bearing race in the housing outlet.

The outer diameter of the bearing: 72.1 mm

13. Apply a thin coat of silicone sealant TB-1217B on interfaced surfaces of the converter housing and transmission housing.

14. Install new O-ring on the cover of the inverter.

A warning

Make sure that the sealant will be forced into the channels for lubrication when installing the gearbox.

15. Secure the gearbox housing to the housing of the converter.

Torque: 38-51 N ??? m

16. To support the turbine shaft, set the special adaptation OK201 190 019.

17. Install the turbine shaft and the block of coupling 3-4:
a. assemble the turbine shaft and the block of coupling 3-4;
b. check that the axial bearing is installed properly;
c. install the turbine shaft and the block of coupling 3-4 in the gearbox housing as an assembly.

18. Install the inner gear:
a. Establish an internal gear in the housing outlet;
b. Install the snap ring.

19. Establish planetary assemblage:
a. check that the axial surface of the bearing and the bearing installed properly;
b. one hand hold the turbine shaft from turning;
c. Install the planetary assembly and 3-4 clutch drum by turning it.

20. Install the brake tape of the lower gears, reverse gear and drive plate.

21. Install the mounting plate.

22. Install the snap ring.

23. Install the friction disk.

24. Install one-way clutch ?��2:
a. keep one-way clutch ?��2 horizontally;
b. install it, turning the planetary assembly counterclockwise;
c. Install the snap ring.

25. Place the rack and the anchor shaft.

A warning

Castle 2-4 brake band and the anchor desk bursting, as shown in the figure.

26. Install the brake band 2-4 in the gearbox so that the tape was completely free.

27. Install the small sun gear and one-way clutch ?��1:
a. check that the axial surface of the bearing and the bearing mounted in the correct position;
b. turning, set small sun gear and one-way clutch ?��1.

28. Install clutch forward / reverse:
a. check that the axial bearing is installed in the correct position;
b. turning, set the clutch forward / reverse.

A warning

Installation height clutch forward / reverse with respect to the flange of the gearbox is different.

Maximum height: 0.9 mm

29. Install the snap ring in the groove of the turbine shaft.

30. Measure the clearance between the flange and the end of the rolling bearing follows:
a. install the bearing on the clutch forward / reverse;
b. remove preset rolling surface and a lining;
c. Install the thickest gasket (2.2 mm) on the oil pump;
d. Install the oil pump assembly clutch without installing the lining of the oil pump;
e. A measure the gap between the transmission case and the oil pump;
f. in accordance with the measured gap, select a specific pad thickness

A clearance, mm	Strip Thickness, mm
0.091 - 1.01	12
0.71 - 0.90	14
0.51 - 0.70	16
0.31 - 0.50	18
0.11 - 0.30	20
0 - 0.10	2.2

31. Remove the oil pump, and then install the bearing surface and a new gasket on the oil pump.

32. Establish the oil pump on the gearbox.

Torque: 19-25 N ??? m

33. Check the adjustment of the brake bands 2-4 as follows:
a. Install the servo piston in the adaptation OK201 190 021;
b. Install the O-ring on the holder with servo adaptation OK201 190 021;

c. lubricate the O-ring fluid for automatic transmissions and install the assembly tapes with servo device in the gearbox housing and secure with snap ring.
d. Establish a measuring tip of the indicator of hour type in an end face of the piston rod;

e. supplies compressed air through the fluid supply duct with an air nozzle sealed with rubber and measure the progress bar;

Air pressure: max 392 kPa
Progress bar: 1.0-7.0 mm
f. if progress bar is not correct, select the appropriate rod;

The length of the piston rod in mm: 95.0, 95.5, 96.0, 96.5, 97.0, 97.5, 98.0, 98.5, 99.0
g. Remove the tape actuator assembly with the device.

A warning

When removing do not damage the snap ring.

34. Install the actuator on the gearbox housing:
a. Install the spring and the servo actuator assembly.
b. Install the snap ring.
c. Install the brake band 2-4 in the servo piston rod.

35. Align the mechanical valve with the pin on the plate and set the control valve body.

The inhaling moment: 7,9-10,7 N ??? m
The length of the bolts (measured from the base of the head):
A: 30 mm
B: 50 mm
C: 14 mm

36. Connect the solenoid valve and temperature sensor connector fluid in an automatic transmission.

37. Connect the solenoid valve.

A warning

Install the magnets in the oil pan in the areas shown in the figure.

38. Install a new gasket and oil pan, and secure it with screws nineteen.

The inhaling moment: 8,4-10,7 N ??? m

39. Install the inlet and outlet pipe.

40. Install the speed sensor and the speedometer driven gear.

41. Install the steering angle sensor of the crankshaft.

42. Install the bracket.

43. Set the range of a transmission:
a. manually turn the shaft in position N;
b. set the switch range of a transmission;
c. Tighten the range selector gearbox;

The inhaling moment: 7,9-10,7 N ??? m
d. check that the position of the selector lever and the indicator chosen position coincide.

44. Remove the gearbox with special adaptation 130,990,007 / OK130 175 011A.

45. Install new O-ring and tube level indicator and oil filling.

The inhaling moment: 7,9-10,7 N ??? m

46. Set speed sensor turbine inlet.

The inhaling moment: 7,9-10,7 N ??? m

47. Install the oil pump shaft.

48. Install the O-ring on the shaft of the turbine.

49. Fill the fluid converter automatic transmission.

Type of liquid for an automatic transmission: M-lll or dexron III

A warning

When filling liquid keep the unit vertically. Do not pour liquid. If the converter is not installed easily, do not apply to his great efforts, install carefully.

50. Install the drive converter housing, turn it to align the grooves.

51. Check the correct installation of the transmitter, measuring the distance A between the end of the converter and the gearbox flange.

Distance A: 13.6 mm

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