Kia Picanto: Manual Transaxle System / Manual Transaxle

Kia Picanto JA 2017-2024 Service & Repair Manual / Manual Transaxle System / Manual Transaxle System / Manual Transaxle

Components and components location
Components

1. Control shaft complete
2. Control cable bracket
3. Transaxle support bracket
4. Roll rod bracket

5. Roll rod support bracket
6. Clutch tube bracket
7. Clutch release cylinder assembly

Repair procedures
Removal
1.
Remove the battery and battery tray.
G 1.0 T-GDI KAPPA (Refer to Engine Electrical System - "Battery")
2.
Disconnect the back up lamp switch (A).

3.
Remove the wiring from the bracket (A).

4.
Remove the control cable.
(1)
Remove the control cable from the control shaft after removing the pins (A).
(2)
Loosen the control cable bracket bolts (B).
Tightening torque:
14.7 - 21.6 N·m (1.5 - 2.2 kgf·m, 10.8 - 15.9 lb·ft)

5.
Remove the ground bolt (A).
Tightening torque :
26.5 - 32.4 N·m (2.7 - 3.3 kgf·m, 19.5 - 23.9 lb·ft)

6.
Loosen the starter mounting bolts (A) and the transaxle mounting bolts (B).
Tightening torque :
(A) : 49.0 - 63.7 N·m (5.0 - 6.5 kgf·m, 36.2 - 47.0 lb·ft)
(B) : 42.2 - 54.0 N·m (4.3 - 5.5 kgf·m, 31.1 - 39.8 lb·ft)

7.
Remove the air cleaner assembly.
G 1.0 T-GDI KAPPA (Refer to Engine Mechanical System - "Air Cleaner")
8.
Remove the cowl top cover.
(Refer to Body - "Cowl Top Cover")
9.
Remove the wiper motor.
(Refer to Body Electrical System - "Front Wiper Motor")
10.
Remove the cowl top panel (A).

11.
Install the engine support fixture on the engine room.
(1)
Install the SST (09221-A3100).

(2)
Loosen the engine mounting bracket bolt (A).
Tightening torque :
49.0 - 63.7 N·m (5.0 - 6.5 kgf·m, 36.2 - 47.0 lb·ft)

(3)
Assemble the engine support fixture on the engine room.

12.
Support the transaxle safely on a jack.

13.
Remove the cover (A).

14.
Loosen the transaxle mounting bracket bolts (A).
Tightening torque :
88.3 - 107.9 N·m (9.0 - 11.0 kgf·m, 65.1 - 79.8 lb·ft)

15.
Remove the transaxle support bracket (A).
Tightening torque :
58.8 - 78.5 N·m (6.0 - 8.0 kgf·m, 43.4 - 57.9 lb·ft)

16.
Remove the under cover.
G 1.0 T-GDI KAPPA (Refer to Engine Mechanical System - "Engine Room Under Cover")
17.
Remove the drive shaft assembly.
(Refer to Driveshaft and Axle - "Front Driveshaft")
18.
Remove the clutch tube bracket bolt (A).
Tightening torque :
14.7 - 21.6 N·m (1.5 - 2.2 kgf·m, 10.8 - 15.9 lb·ft)

19.
Disconnect the neutral switch connector (A).

20.
Remove the exhaust manifold stay (A).
Tightening torque:
39.2 - 49.0 N·m (4.0 - 5.0 kgf·m, 28.9 - 36.2 lb·ft)

21.
Remove the clutch release cylinder assembly (B) after removing the bolts (A).
Tightening torque:
14.7 - 21.6 N·m (1.5 - 2.2 kgf·m, 10.8 - 15.9 lb·ft)

22.
Loosen the intercooler pipe mounting bolts (A).
Tightening trorque :
6.9 - 10.8 N·m (0.7 - 1.1 kgf·m, 5.1 - 8.0 lb·ft)

23.
Remove the roll rod bracket (A) after removing bolt (B, C).
Tightening torque
(B) : 49.0 - 63.7 N·m (11.0 - 13.0 kgf·m, 36.2 - 47.0 lb·ft)
(C) : 107.9 - 127.5 N·m (5.0 - 6.5 kgf·m, 79.6 - 94.0 lb·ft)

24.
Remove the roll rod support bracket (A).
Tightening torque:
49.0 - 68.6 N·m (5.0 - 7.0 kgf·m, 36.2 - 50.6 lb·ft)

25.
Support the transaxle safely on a jack.
26.
Loosen the transaxle lower mounting bolts (A, B).
Tightening torque
(A) 48.1 - 53.9 N·m (4.9 - 5.5 kgf·m, 35.4 - 39.8 lb·ft)
(B) 42.2 - 54.0 N·m (4.3 - 5.5 kgf·m, 31.1 - 39.8 lb·ft)

27.
After separating the transaxle from the engine, remove the transaxle by lowering the jack slowly.
   
Be careful not to damage other nearby systems or parts when removing the transaxle assembly.
Installation
   
In case of oil leakage due to damaged differential oil seal, replace the oil seal with a new one by using special tools
1.
Install in the reverse order of removal.
Manual Transaxle Oil
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Back-up Lamp Switch
Specifications Specifications Item Specified Type ON/OFF Operating condition Reverse gear Operating voltage 10V - 15V Operating ...

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