Mechanics

HOW TO DROP TRANSMISSION

2002 Kia Sportage

Transmission problem
2002 Kia Sportage 4 cyl Four Wheel Drive Manual 120 miles

Diagram how to remove transmission to be able to put new clutch Disc
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Bola27616
March 19, 2009.



TRANSMISSION
Removal
Disconnect the negative battery cable.
Disconnect the A/T control cable from the throttle body (engine compartment) as follows: Remove one bolt and remove the air silencer.
Provide A/T control cable slack by gently pulling the cable to the left until the cable pin has rotated sufficiently to line the A/T control cable up with the slot in the rear of the throttle body bellcrank.
Slide the A/T control cable and cable pin to the rear and out of the throttle body bellcrank. Take care not to pinch or deform the cable.
Loosen the lock nut and remove the throttle kickdown cable from the mounting bracket.
Place the A/T control cable to the side, where it can be slid out through the bottom of the engine compartment.
Slide the front seats forward to allow access to the two rear shift console mounting screws (located at the rear of the console, on the bottom of the sides).
Set the parking brake.
Remove the rear console mounting screws. Remove the rear console by pulling up on the rear (ashtray) end and sliding the rear console slightly forward, and up. The parking brake will slip through the slot in the rear console.
Slide the front seats as far back as possible to allow access to the forward two front console mounting screws (located at the front of the console, on the bottom of the sides). Remove the two front console mounting screws as well as the third screw located at the rear of the console, centered on the bottom of the console. Untie the leather boot draw strings around the transfer case shift lever and open the boot up fully to allow it to slip over the transfer case shift lever knob.
NOTE: Open the boot carefully to avoid damaging it.

Loosen the transfer case shift lever lock nut and unscrew the transfer case shift lever knob by turning it counterclockwise.
Pull the rear of the front console up and slightly to the rear until the POWER/ECONOMY switch connector is exposed, then disconnect the connector from the switch. Remove the front console.
Shift the transfer lever to the 4L position.
Remove the four transfer shift lever cover plate bolts.
Remove the cover plate and underlying boot by lifting them up.
Remove the five top retaining bolts.
Lift the transfer case shift lever assembly straight out. NOTE: To prevent damage to the opening of (or dropping foreign objects into) the transfer case, cover the transfer case opening with a piece of plastic, cardboard, etc. (Secured in place with tape).

Shift the transmission shift selector into " P" range and remove the four selector lever nuts. Raise and properly support the vehicle.
Remove the transmission fluid drain plug and drain the ATF into a suitable container. NOTE: Once the ATF is drained, reinstall the drain plug to prevent further dripping.

Remove the split pin from the shift selector lever.
Remove the shift selector rod, as well as the two spring washers (one in front of, and one behind the selector rod) from the shift selector lever. NOTE: Do not lose the split pin or the washers.

Lower the vehicle.
Disconnect the four connectors from below the selector lever.
NOTE: There is a fifth wire connection (Park Position) that is hard-wired. DO NOT disconnect this wire.

NOTE: It should not be necessary to exert any force to remove the selector lever assembly. Doing so could bend/damage the connecting shaft to the selector rod.

Remove the selector lever assembly as follows: Slide the assembly to the right as far as possible (about 2-3" ).
Tilt the assembly to the left (counterclockwise).
Lift up slightly and push forward (assembly still tilted counterclockwise).
Simultaneously slide the assembly to the right, pull up gently, and tilt the assembly gradually clockwise (it will tilt a little naturally).
Clear the shift selector rod pin, and remove the assembly.
Set the assembly in a safe place.
In the engine compartment, disconnect the A/T control cable from the throttle linkage by opening the throttle bellcrank fully, and sliding the end of the cable out of the bellcrank. See Fig. 1.
Pull the upper transmission dipstick tube free of the lower transmission dipstick tube.
Raise and properly support the vehicle.
WARNING: When the transmission is removed from the vehicle, the center of gravity will shift forward significantly. To avoid having the vehicle tip off the lifting/supporting device(s), the recommended lift points should be the two main front to rear frame members on each side of the vehicle, at each end, placed so that the lifting/supporting device(s) come into full contact with the last fully horizontal surface of the frame members. This is just behind the front wheels and just in front of the fear wheels.

Disconnect all electrical wiring located on the transmission, except for the 4x4 position indicator, position indicator lamp switch, and HOLD switch. These connections will be disconnected at a later time. Do not remove the transmission before disconnecting these connectors.
Remove the front and rear drives hafts as follows: Make an alignment mark on the drive shaft flange and on the differential flange.
Remove the four bolts that connect the rear differential to the drive shaft, and the four bolts that connect the drive shaft to the transfer case.
From the differential side, push the drive shaft towards the transmission until it clears the differential flange nut (located in the center of the differential flange).
Drop the rear of the drive shaft down until it is below the differential flange.
Pull the drive shaft away from the transfer case.
NOTE: Keep the bolt and nut combinations with their respective flanges for proper reassembly. Repeat the preceding procedure for the front drive shaft.

Remove the two (oil cooling pipe) clamp nuts and the two outer clamps.
NOTE: There will be a significant amount of ATF fluid in the oil cooler lines. Position the drip pan directly under the oil cooler lines at the transmission connections before proceeding.

Disconnect both cooling lines from the transmission. While holding the transmission end of the lines over the drip pan, free the line from the clamps with the other hand. Lower the free line ends until they are supported by the drip pan (preferably not in the ATF fluid in the pan). Allow the transmission fluid to fully drain from the lines. Place a shop towel under the oil cooler lines at the radiator connections. Disconnect the transmission oil cooler lines from the radiator and remove them from the vehicle.
Remove the starter motor. See STARTERS article in ELECTRICAL.
Remove the two transfer case mounting bolts (located on the passenger side, center of the transfer case). Remove the four transfer case nuts from the crossmember.
Place a transmission jack under the transmission oil pan, as close to the crossmember as possible. Extend the jack, and secure the transmission to the transmission jack. Remove the eight crossmember mounting bolts (four on each side).
Remove the crossmember from the vehicle. Remove all transmission mounting bolts (bottom to top) from the engine.
NOTE: When removing the two lower passenger side bolts, the passenger side gusset will drop free. The upper driver side exhaust bracket bolt requires a 21" extension, universal joint, and 14-mm socket. Access to the bolt is gained from behind and above the lower portion of the transmission dipstick tube, outside of the selector rod. Loosen the lower exhaust bracket mounting bolt, and slip the bracket out of the way after the top two mounting bolts have been removed. The remaining upper driver side mounting bolts require a 17-mm socket, universal joint, and 40" of extensions (two 20" extensions, etc.). Access to the bolts is gained from between the selector rod and transmission housing, driver side, at the rear section of the transmission oil pan. The transmission needs to be " hanging" to provide maximum tool clearance. (Do not remove the transmission jack, just lower it). The upper passenger side mounting bolts require a 17-mm socket, universal joint, and 20" extension. Access to the bolts is gained from below the transmission, beside the gear box, on passenger side. The transmission needs to be " hanging" to allow maximum tool clearance. Do not remove the transmission jack, just lower it.

Once all the transmission-to-engine mounting bolts have been removed, raise the transmission until it is level (as close to it's original position as possible, with the converter housing equally spaced against the engine block).
Remove the four front lower splash guard mounting bolts, and remove the lower front splash guard.
Remove the driver side lower gusset to allow access to the driver side torque converter inspection cover bolt. Remove two torque converter inspection cover bolts and remove the converter inspection cover.
Remove six torque converter-to-drive plate mounting bolts.
NOTE: This requires hand cranking the engine using a 21-mm deep socket and ratchet at the crankshaft pulley to gain access to the torque converter bolts. Slide the transmission away from the engine approximately 2-3", as necessary to gain access to these bolts.

Simultaneously slide the transmission away from the engine as far as possible (without forcing), and slowly lower the transmission slightly.
NOTE: Only lower the transmission enough to gain access to the upper electrical connectors, and to the crankshaft position sensor (located on the converter housing, driver side, near the top). Lowering the transmission too far at this point could result in damaging the crankshaft position sensor, wire, or any/all of the three remaining connectors.

Remove the crankshaft position sensor bolt and remove the crankshaft position sensor.
Slowly lower the transmission (guiding the A/T control cable out of the engine compartment until it is clear).
Disconnect the 4WD indicator switch, 4WD low switch, and vehicle speed sensor harness connectors. NOTE: Continuously check above and around the transmission as you lower it, to make sure all connectors have been disconnected, and that nothing is getting caught, or " hung-up" as the transmission lowers. Disconnect any connected electrical connectors, and free anything that becomes caught by the transmission before continuing to lower the transmission. Failure to do so could result in damage to the transmission, electrical wiring, or the vehicle itself.

WARNING: With the transmission out of the vehicle, the center of gravity will shift forward significantly. Depending on exactly where the lift points have been placed, failure to observe the preceding notice could potentially tip the vehicle, resulting in severe or fatal injury to personnel.

Installation
With the vehicle raised and properly supported and the transmission on a transmission jack, slowly raise the transmission until you can connect the 4WD Indicator switch and 4WD Low switch connectors on the top of the transmission. Guide the A/T control cable into the engine compartment until it is in position.
NOTE: Only raise the transmission enough to connect the upper electrical connectors, and the crankshaft position sensor (located on the converter housing, driver side, near the top) at this time. Continuously check above and around the transmission as you raise it, to make sure all connectors have been connected, and that nothing is getting caught, or " hung-up" as the transmission goes in. Free anything that becomes caught by the transmission before continuing to raise the transmission. Failure to do so could result in damage to the transmission, electrical wiring, or the vehicle itself.

Connect the 4WD indicator switch and 4WD low switch connectors, located at the rear of the transmission, top, passenger side. It connects to the black connector. Connect the input/turbine speed sensor, shift solenoid valves, and vehicle speed sensor connectors (all located on the driver side of the transmission).
Install the crankshaft position sensor and bolt (near top of converter housing, driver side). Tighten to specification. See TORQUE SPECIFICATIONS.
Simultaneously slide the transmission towards the engine as far as possible (without forcing), and slowly raise the transmission as needed to align the converter housing bolt holes with the engine mounting holes.
Install the upper transmission-to-engine mounting bolts (M10 and M12 bolts). Tighten to specification. See TORQUE SPECIFICATIONS.
NOTE: The upper driver side mounting bolts require a 17-mm socket, universal joint, and 40" of extension (two 20" extensions, etc.). Access is from between the selector rod and transmission housing, driver side, just behind the transmission oil pan. The upper passenger side mounting bolts require a 17-mm socket, universal joint, and 20" extension. Access is from below the transmission, immediately behind the transmission oil pan, on the passenger side.

Using the exhaust hanger bolt (with washer and spacer), install the exhaust bracket to the exhaust hanger. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the exhaust bracket (though the converter housing) to the engine with two mounting bolts and tighten to specification. See TORQUE SPECIFICATIONS.
The upper driver side exhaust mounting bolt requires a 14-mm socket, universal-joint, and 21" extension. Access is from behind and above the point where the lower transmission dipstick tube enters the transmission oil pan, outside of the selector rod.
Install the oil cooling pipe rear clamp onto the lower driver side engine mounting hole with one engine mounting bolt. Tighten to specification. See TORQUE SPECIFICATIONS.
Raise the rear of the transmission with the transmission jack. Install the crossmember. Install the eight (four on each side) crossmember mounting bolts. Tighten to specification. See TORQUE SPECIFICATIONS.
Lower the transmission on to the crossmember, making sure that the transfer case mounting bolts slip into the crossmember mounting holes.
Install the two transfer case mounting bolts (located on the passenger side, center, of the transfer case). Tighten to specification. See TORQUE SPECIFICATIONS.
Install the transfer case-to-crossmenber mounting nuts (4). Tighten to specification. See TORQUE SPECIFICATIONS.
Install six torque converter mounting bolts. See Fig. 15. Tighten to specification. See TORQUE SPECIFICATIONS.
NOTE: This requires hand cranking the engine using a 21-mm deep socket and ratchet to gain access to all six converter bolt positions.

Install the torque converter inspection plate with two bolts. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the torque converter dust cover with two bolts. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the driver side lower gusset with four bolts. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the starter. See STARTERS article in ELECTRICAL.
Install the passenger side lower gusset and intake manifold support bracket as follows: Install the bottom of the gusset with two converter housing-to-gusset mounting bolts, but do not tighten yet.
Secure the intake manifold support bracket in place with two bolts through the lower gusset-to engine block mounting holes. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the third intake manifold support bracket mounting bolt through the intake manifold support bracket and into the intake manifold. Tighten to specification. See TORQUE SPECIFICATIONS.
Position the oil cooler pipes in place and secure with the two oil cooler pipe clamp caps, and two nuts. Tighten to specification. See TORQUE SPECIFICATIONS.
Connect the two oil cooler pipes to the radiator with the two hose clamps provided.
Connect both oil cooling pipes to the transmission. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the under cover (lower splash guard) with the four undercover mounting bolts. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the front and rear drive shafts as follows: Raise the forward drive shaft into place, mating the flanges.
Install the four drive shaft-to-differential mounting bolts. Tighten to specification. See TORQUE SPECIFICATIONS.
Push the drive shaft toward the transfer case until the flanges make full contact.
Install four drive shaft-to-transfer case mounting bolts. Tighten to specification. See TORQUE SPECIFICATIONS.
Repeat the above procedure for the rear drive shaft.
Insert the upper transmission dipstick tube into the lower transmission dipstick tube.
Lower the vehicle.
Connect the A/T control cable to the throttle linkage as follows: With the air silencer removed, position the A/T control cable into it's bracket, but do not tighten the lock nut.
Gently pull the cable to the left until you have enough slack to insert the cable pin into the throttle body bell crank (from the rear). The cable will fit through the slot at the bottom of the throttle body bell crank. Take care not to pinch or deform the cable.
Verify the cable adjustment. See ADJUSTMENTS in appropriate SERVICING article.
Install the air silencer with one bolt. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the air silencer hose. Secure the screw clamp.
From inside the vehicle, carefully install the shift selector lever assembly.
Connect the three position switch connectors, but do not connect the power/economy switch connector at this time.
Shift the selector lever into the " P" range, and from underneath the vehicle, connect the selector rod to the selector lever with a split washer (inside), a flat washer (outside), and the split pin.
NOTE: Do not connect the power/economy switch connector at this time.

Remove the cover installed on the transfer case opening during disassembly.
Align the transfer case shift lever tang into it's appropriate slot, slip the transfer shift lever assembly straight into the transfer case, aligning the 5 mounting bolt holes (the shift lever tang should fit into it's slot easily, if not, the transfer lever assembly will not set down into the transfer case).
Install the five transfer case shift lever mounting bolts. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the transfer lever cover plate and underlying boot. Install the four transfer case shift lever cover plate bolts. Tighten to specification. See TORQUE SPECIFICATIONS
Position the front console in place.
Connect the power/economy connector to the power/economy switch in the front console.
Secure the front console with three screws (two on the front, bottom sides; one at the rear, bottom, center).
Install the transfer case shift lever knob by turning it clockwise until it stops. Back it off until the shift pattern printed on top is horizontally straight. Lock it in this position using the transfer case shift lever lock nut.
Tie the leather boot draw strings around the transfer change lever shaft.
Slide the front seats as far forward as possible to gain access to the rear console mounting screw holes.
Set the parking brake and install the rear console. The parking brake lever will slip through the slot in the rear console.
Install the two rear console mounting screws.
Fill the transmission with appropriate fluid to proper level. See appropriate SERVICING article.
Connect the negative battery cable.
Start engine and check transmission fluid level. Adjust as needed.

Dave H
Mar 21, 2009.