KIA M6GF2 Sportage Transaxle System Instruction Manual

KIA M6GF2 Sportage Transaxle System

Specifications

Tightening Torgues 

Item	N.m	kgf.m	lb-ft
Oil drain plug bolt	58.9~78.5	6.0~8.0	43.4~57.9
Oil filler plug bolt	29.4~34.3	3.0~3.5	21.7~25.3
Shift lever assembly bolt	8.8~13.7	0.9~1.4	6.5~10.1
Back up lamp switch	29.4~34.3	3.0 ~ 3.5	21.7~25.3
Transaxle mounting bracket       88.3~107.9        9.0~11.0          65.1~79.6 bolt Strut motor installation bolt             42.2~53.9           4.3~5.5           31.1~39.8 Transaxle upper mounting bolt    42.2~53.9           4.3~5.5           31.1~39.8 (TM=>ENG) Transaxle lower mounting bolt    42.2~48.l           4.3~4.9          31.1~35.4 (ENG=>TM)                                42.2~53.9          4.3~5.5          31.1~39.8

Lubricants 

Special Service Tools

Repair procedures

Inspection
Manual transaxle oil Inspection

1.  Park the vehicle on a level ground and stop the engine.
2.  Retighten the oil filler plug(A) with a new washer.
   
3. Check level with finger.
   Note: Oil level must be up to fill the hole, if not, add oil until it mns over.
   
4. Retighten the oil filler plug(A) with a new washer.

Tightening torque : 29.4~34.3N.m (3.0~3.5kgf.m, 21.7~25.3lb-ft)

Manual transaxle oil replacement

1. Park the vehicle on a level ground and stop the engine.
2. Drain the manual  oil after loosening the drain plug (A).
   
3. Install the drain plug with new gasket.
   Tightening torque : 58.9~78.5N.m (6.0~8.0kgf.m, 43.4~57.9lb-ft)
4. Add new oil through the filler plug hole and, fill it just below the plug opening. Standard oil: SAE 75W/85, API GL-4
   Oil capacity: 1.8L(0.48 U.S. gal.,1.90 U.S. qt., 1.58hnp. qt.)

Components and Components Location

Components 

1. Manual transaxle case
2. Concentric slave cylinder
3. Clutch housing
4. Shift. cable bracket assembly
5. Conol complete shaft
6. Back-up lamp switch

Removal 

1. Remove the following items;
   1. Engine cover (A). (Refer to “Intake and Exhaust system” in EM group.)
   2. Air cleaner assembly and air duct(B) . (Refer to “Intake and Exhaust system” in EM group.)
   3. Batte1y and batte1y tray (C). (Refer to “Charging system” in EE group.)
      
2. Remove the ground (A) .
   
3. Disconnect the cable assembly (A) after removing the clips (B) and pins (C).
   
4. Disconnect the concentric slave cylinder tube(A) after removing the pins(B).
   
5. Remove the wiring bracket bolt (A).
   
6. Remove the cowl top cover or wiper motor. (Refer to “Windshield Wiper/Washer” in BE group.)
7. Remove the cowl complete assembly panel(A).
   
8. Using the engine supp01t fixture (Supp01t SST No.: 09200-2S000, Beam SST No.: 09200-38001), hold the engine
   
9. Remove the transaxle upper mounting bolt (A-2ea) and the start motor mounting bolt (B-2ea).
   Tightening torque: 42.2~53.9N.m (4.3~5.5kgf.m, 31.1~39.8lb-ft)
   
10. Supp01ting the transaxle with a jack, remove the mounting bolts(A).
    Tightening torque : 88.3~ 107.9N.m (9.0~ 11.0kgf.m, 65.1~ 79.6lb-ft)
    
11.  Remove the under cover (A).
    Tightening torque: 19.6-21.6N.m (2.0~2.2kgf.m, 14.5~15.9lb-ft)
    
12. Remove the side cover(A).
    
13. Remove the roll rod bracket(C) after removing bolt(A,B).
    Tightening torque :
    1. (B) 49.0~63.7N.m (5.0~6.5kgf.m, 36.2~47.0lb-ft)
    2. (D) 107.9~127.5N.m (11~13kgf.m, 79.6~94.llb-ft)
14. Remove the following items;
    1. Drive shaft assembly. (Refer to “Drive shaft assembly” in DS group.)
    2. Sub frame assembly. (Refer to “Front suspension system” in SS group)
    3. In the case of 4WD vehicle, remove the transfer assembly. (Refer to “Transfer assembly” in WD group)
       In the case of 2WD vehicle, not remove the transfer assembly.
       
15. Remove the mounting bolts(A-4ea, B-2ea) of lower pait of the transaxle, ai1d the left side cover and remove the transaxle assembly by suppo1ting it with a jack.
    Tightening torque:
    1. 42.2~48.1 N.m (4.3~4.9kgf.m, 31.1~35.4lb-ft)
    2. 42.2~53.9 N.m ( 4.3~5.5kgf.m, 31.1 ~39.8lb-ft)
       
       

Installation
Installation is the reverse of removal.

• Adding Manual transaxle fluid. (Refer to “Manual transaxle system” in this group.)
• Perform bleeding air procedure in concentric slave cylinder after pouring the brake fluid.(Refer to “Concentric slave cylinder” in CH group.)

Manual Transaxle System > Manual Transaxle Control System> Back-up Lamp Switch> Description and Operation

Description
Back up lamp switch is pushed by the reverse lug sliding when select arm, ar1d switches the back up lamp.

Back-up Lamp Switch > Specifications Specifications

1. Working voltage: DC 10~15V
2. Operating force : 3.0kg Max.
3. Voltage drop: – 0.4V
4. Working temperature: -30°C ~ 100°C [-30°F ~ 212°F]

Back-up Lamp Switch > Repair procedures

Inspection

1. Disconnect the back up larnp switch connector(A).
   
2. Check the continuity between no. 1 and 2 terminals of backup larnp switch. When the shift lever is in reverse, there should be continuity.
3. If necessaiy, repair or replace the backup lainp switch.
   

Replacement

1. Disconnect the back up lamp switch connector(A).
   
2. Remove the back up lamp switch (A).
   
3. Replace a new one and install the back up lamp switch.
   Tightening torque : 29.4~34.3N.m (3.0~3.5kgf.m, 21.7~25.3lb-ft)

Shift Lever> Components and Components Location

Components

1. Shift lever knob & boot assembly
2. Shift lever assembly
3. Shift cable assembly
4. Select cable assembly
5. Retainer

Shift Lever> Repair procedures

Removal
Shift Lever Assembly Replacement

1. Remove the floor Interior console assembly. (Refer to “Interior(Console)” in BD group)
2. Remove the select cable snap pin (A) and the clip (B) from the select cable assembly.
   
3. Remove the clip (A) from the shift cable assembly.
   
4. Remove the shift lever assembly(B) after removing shift lever assembly installation bolt(A).
   Tightening torque : 8.8~13.7N.m (0.9~1.4kgf.m, 6.5~10.llb-ft)
   
5. Installation is the reverse of removal.
   Make sure vehicle does not roll before setting room side shift lever and T /M side manual control lever to ”N” position.

Shift Cable Replacement 

1. Remove the floor Interior console assembly. (Refer to “Interior(Console)” in BD group)
2. Remove the select cable snap pin (A) and the clip (B) from the select cable assembly.
   
3. Remove the clip (A) from the shift cable assembly.
   Tightening torque : 8~1 l.8N.m (0.8-1.2kgf.m, 5.8~8.7lb-ft)
   
4. Remove the cable(B) from the cable bracket(A) at manual transaxle assembly side.
5. Remove the pins(C).
6. Remove the shift cable and select cable at cabin room.
7. Installation is the reverse of removal.Make sure vehicle does not roll before setting room side shift lever and TIM side manual control lever to ”N” position.

Inspection 

1. Check the select cable for proper operation and for damage.
2. Check the shift cable for proper operation and for damage.
3. Check the boots for damage.
4. Check the boots for wear abrasion sticking, restricted movement or damage.
5. Check for the weak or damaged spring.

Adjustment

1. Install the guide member (A) of the select cable (B).
   
2. Adjust the slide clip (B) to fit it into the select lever pin (A) and install the snap pin (C).
   
3.  Remove neutral position pin (A) after shift lever assembly.
   

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