AT Diagnosis PDF

2003 Kia Sorento LX
2003 AUTOMATIC TRANSMISSIONS 30-40LEI - Diagnosis & Overhaul
2003 AUTOMATIC TRANSMISSIONS
30-40LEI - Diagnosis & Overhaul
GENERAL
SPECIFICATION
Fig. 1: Transaxle Specifications

Courtesy of KIA MOTORS AMERICA, INC.
TIGHTENING TORQUE
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Fig. 2: Tightening Torque Specifications

SPECIAL SERVICE TOOLS
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Fig. 3: Special Service Tools (1 Of 3)

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AUTOMATIC TRANSMISSION FLUID
1. Inspection:
1. Apply the parking brake and position wheel chocks to prevent the car from rolling forward.
NOTE: Place the car on a flat, level surface.
2. Run the engine to heat the automatic transmission fluid to 70-80°C (158-176°F).
While the engine is idling, shift the selector lever from "P" to "L" and back again.
3. Let the engine idle.

4. Shift the selector lever to "P" or "N"
5. Check that the ATF level is in the 75°C (158°F) range. Add ATF to specification if necessary.
2. Condition:
1. Check the ATF for discoloration.
2. Check the ATF for any unusual small.
NOTE: Determine whether or not the automatic transmission should be disassembled,

by carefully observing the condition of fluid.
If the fluid is muddy and varnished, it indicates burned drive plates.
SYSTEM DIAGRAM
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Fig. 6: Electrical System Diagram

HYDRAULIC CONTROL SYSTEM
Based on the hydraulic pressure created by the oil pump, TCM sends signals to solenoid and hydraulic control
system governs the hydraulic pressure acting on the torque converter, planetary gear, clutches and brakes in
accordance with the vehicle driving conditions.
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Fig. 7: Hydraulic Control System Diagram

PRELIMINARY TESTING
SELF-DIAGNOSIS DESCRIPTION
1. When malfunction is detected in the electronic control system, the concerned parts and wires should be
inspected individually. It takes a lot of time resulting in automotive engineers and drivers to
inconvenience. To cope with it, computer detects the malfunctions and generates them as code so that
engineer can troubleshoot easily.
2. Not all malfunctions of the vehicle are detected by Self-diagnosis. When the malfunction is completely
presented like faulty parts of sensor or short/open wiring, detection will be easy. But when intermittent
abnormality or short wiring occurs, self-diagnosis can't detect the errors even though the vehicle has
problem.
3. The above 2 is caused by timing difference between outputs of input signal for controlling by computer
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and self-diagnosis. So while using self-diagnosis, be careful not to make a mistake.
SELF-DIAGNOSIS PROCEDURE
SELF-DIAGNOSIS USING HI-SCAN
1. Using Hi-scan:
1. Connect a Hi-scan to the self-diagnosis connector on the engine room OBD connector (the lower
inside of crash pad in driver's side).
DIAGNOSTIC TROUBLESHOOTING CODE CHART
Fig. 8: Diagnostic Troubleshooting Code Description Chart

Fault type:
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z TYPE A: DTC stored on the 1st driving.

z TYPE B: DTC stored on the 2nd driving.
z TYPE C: only fail-safe (Not DTC stored).
Warning lamp (W/L): O/D OFF lamp.
MIL/Warning:
"O" - Supported (To be performed at the dame time as DTC store).
"-" - Not supported.
LINE PRESSURE
1. Connect a tachometer to the engine and SST to line pressure inspection port of transmission case.
2. Shift the selector lever to "D" range.
3. Read the oil pressure at engine idle speed.
4. Depress the brake pedal firmly with the left and gradually depress the accelerator pedal with the right
foot.
5. Read the oil pressure as soon as the engine speed becomes constant, then release the accelerator pedal.
NOTE: Steps 4 to 5 must be accomplished within 5 seconds.
6. Shift the selector lever to "N" range and run the engine at idle speed for at least one minute.
7. Read the line pressures at engine idle and stall speed for "R" range in the procedure described above.
Fig. 9: Line Pressure Specification Chart

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Fig. 10: Line Pressure Test Evaluation

STALL TEST
The object of this test is to check the overall performance of the transmission and engine by measuring the stall
speeds in the "D" and "R" ranges.
CAUTION: During this test, make sure that no one stand in front of or behind vehicle.
1. Check transaxle fluid level. Fluid should be at normal operating temperature [70-80°C (158-176°C)].
Engine coolant should also be at normal operating temperature [80-90°C (176-194°C)].
2. Apply chocks to both rear wheels.
3. Attach an engine tachometer.
4. Apply the parking and service brakes fully.
5. Start the engine.
6. With the selector lever in the "D" position, depress the accelerator pedal fully to read maximum engine
RPM. Do not hold the throttle wide open any longer than is necessary to obtain maximum engine RPM
reading, and never longer than 5 seconds at a time. If more than one stall test is required, operate the
engine at approximately 1,000 RPM in neutral for minutes to cool the transaxle fluid between tests.
7. Place the selector lever in the "R" position and perform the stall test by the same procedure as previously
described.
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Fig. 11: Stall Test RPM Chart

Fig. 12: Evaluation Of Stall Test

TIME LAG TEST
NOTE: If selector lever is shifted while the engine is idling, there will be a certain time
lapse or time lag before shift shock can be felt. This is used for checking
condition of the OD clutch, forward clutch, direct clutch and low & reverse
brake.
PRECAUTION
Engage the parking brake and apply wheel chocks to the front and rear wheels.
1. Shift the selector lever from "N" to "D" range.

2. Using stop watch, measure the time it takes from the moment the lever is shifted until shift shock is felt.
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3. Measure the time lag for "N" to "R": in same manner.
NOTE: Make the measurements and take the average value. Be sure to permit at least
one minute interval between measurements.
STANDARD TIME LAG
Fig. 13: Standard Time Lag Chart

EVALUATION OF TIME LAG TEST
Fig. 14: Evaluation Of Time Lag Test

TCM INPUT AND OUTPUT TERMINAL VOLTAGE TABLE

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Fig. 15: TCM Input & Output Terminal Voltage Table (1 Of 2)

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Fig. 16: TCM Input & Output Terminal Voltage Table (2 Of 2)

TCM WIRING DIAGRAM
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Fig. 17: TCM Wiring Diagram (1 Of 2)

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Fig. 18: TCM Wiring Diagram (1 Of 2)

TESTING & DIAGNOSIS

SPEED SENSOR (OUTPUT)
1. Disconnect the speed sensor connector.

2. Measure the resistance between pin 1 and pin 2.
Resistance: 560-680° (20 °C)
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Fig. 19: Testing Speed Sensor

SOLENOID VALVE
1. Disconnect the solenoid valve connector.

2. Measure the resistance between each terminal and ground.
Resistance: 1-15 ohm
3. If not corrected, replace the solenoid valve.

1. Solenoid valve No. 1.
2. Solenoid valve No. 2.
3. Lock-up solenoid valve.
4. Line pressure sol. valve.
5. Ground for line pressure sol. valve.
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Fig. 20: Solenoid Valve Connector Pinout

INSPECTION PROCEDURES FOR DIAGNOSTIC TROUBLE CODE
DTC INDEX
DTC Description
DTC P0707 & P0708 INHIBITOR SWITCH CIRCUIT
DTC P0710 TRANSMISSION FLUID TEMPERATURE SENSOR
DTC P0716 & P0717 INPUT SPEED SENSOR
DTC P0722 OUTPUT SPEED SENSOR
DTC P0726 & P0727 ENGINE SPEED INPUT
DTC P0740 & P0743 TORQUE CONVERTER CLUTCH SYSTEM
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DTC P0748 PRESSURE SOLENOID

DTC P0750 & P0753 SHIFT SOLENOID NO. 1
DTC P0755 & P0758 SHIFT SOLENOID NO. 2
DTC P1115 WATER TEMPERATURE SIGNAL
DTC P1121 TPS SIGNAL CIRCUIT FROM ECM TO TEM
DTC P1630 CAN COMMUNICATION BUS OFF
DTC P1795 TRANSFER HIGH/LOW (L4) SWITCH
DTC P0707 & P0708: INHIBITOR SWITCH CIRCUIT
Fig. 21: P0707 & P0708 Probable Cause Chart

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Fig. 22: P0707 & P0708 Diagnostic Trouble Chart

DTC P0710: TRANSMISSION FLUID TEMPERATURE SENSOR
Fig. 23: P0710 Probable Cause Chart

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Fig. 24: P0710 Diagnostic Trouble Chart

DTC P0716 & P0717: INPUT SPEED SENSOR

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DTC P0722: OUTPUT SPEED SENSOR

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DTC P0726 & P0727: ENGINE SPEED INPUT

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DTC P0740 & P0743: TORQUE CONVERTER CLUTCH SYSTEM


DTC P0748: PRESSURE SOLENOID
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DTC P0750 & P0753: SHIFT SOLENOID NO. 1
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DTC P0755 & P0758: SHIFT SOLENOID NO. 2
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DTC P1115: WATER TEMPERATURE SIGNAL
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DTC P1121: TPS SIGNAL CIRCUIT FROM ECM TO TEM

DTC P1630: CAN COMMUNICATION BUS OFF

DTC P1795: TRANSFER HIGH/LOW (L4) SWITCH
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DISASSEMBLY & REASSEMBLY

COMPONENTS
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Fig. 43: Illustrating Transaxle Components (1 Of 2)

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Fig. 44: Illustrating Transaxle Components (2 Of 2)

DISASSEMBLY
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1. Remove the torque converter.

2. Remove the oil filler gauge.
3. Remove the wire harness clamp.
Fig. 45: Removing The Wire Harness Clamp

4. Remove the control shaft lever.
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Fig. 46: Removing The Control Shaft Lever

5. Remove the transaxle range switch.
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Fig. 47: Removing The Transaxle Range Switch

6. Remove the union.
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Fig. 48: Removing The Union

7. Remove the output speed sensor.
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Fig. 49: Removing The Output Speed Sensor

8. Remove the input speed sensor.
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Fig. 50: Removing The Input Speed Sensor

9. Remove the transmission housing.
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Fig. 51: Removing The Transmission Housing

10. Remove the extension housing.
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Fig. 52: Removing The Extension Housing

11. Using a dial indicator, measure the inside diameter of the extension housing bushing.
Max.: 40.09 mm (1.5783 in.)
If the inside diameter is greater than maximum, replace the extension housing.
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Fig. 53: Measuring The Inside Diameter Of The Extension Housing Bushing
12. Remove the speedometer drive gear.

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13. Remove the sensor rotor and key.
Fig. 54: Removing The Sensor Rotor & Key

14. Remove the oil pan.
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Fig. 55: Removing The Oil Pan

15. Remove the magnets and use them to collect steel particles.
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Fig. 56: Removing The Magnets

16. Remove the oil strainer and gasket.
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Fig. 57: Removing The Oil Strainer And Gasket

17. Remove the stopper plate.
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Fig. 58: Removing The Stopper Plate

18. Remove the valve body mounting bolts.
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Fig. 59: Removing The Valve Body Mounting Bolts

19. Remove the check ball body, springs (4EA) and pins (2EA).
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Fig. 60: Removing The Check Ball Body, Springs & Pins
20. Remove accumulator springs and pistons:

1. Applying compressed air to the ATF hole, remove the B0 accumulator piston and spring.
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Fig. 61: Removing The B0 Accumulator Piston & Spring

2. Applying compressed air to the ATF hole, remove the C0 accumulator piston and spring.
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Fig. 62: Removing The C0 Accumulator Piston & Spring

21. Remove the oil pump.
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Fig. 63: Removing The Oil Pump

22. Remove the overdrive planetary and the overdrive direct clutch.
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Fig. 64: Removing The Overdrive Planetary And The Overdrive Direct Clutch
23. Remove the overdrive ring gear.
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Fig. 65: Removing The Overdrive Ring Gear

24. Remove the snap ring.
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Fig. 66: Removing The Snap Ring

25. Remove the flanges, the plates and the discs.
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Fig. 67: Removing The Flanges, The Plates & The Discs
26. Using the micrometer, measure the thickness of the disc.
Minimum thickness: 1.84 mm (0.0724 in.)
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Fig. 68: Measuring The Thickness Of The Disc

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28. Applying compressed air to the ATF hole, remove the second coast brake piston.
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Fig. 70: Removing The Second Coast Brake Piston

29. Remove overdrive support:

1. Remove the thrust bearing and race.
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Fig. 71: Removing The Thrust Bearing & Race

2. Remove the overdrive support mounting bolts.
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Fig. 72: Removing The Overdrive Support Mounting Bolts

3. After removing the snap ring, remove the overdrive support.
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Fig. 73: Removing The Overdrive Support Snap Ring

30. Remove the direct clutch and the forward clutch.
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Fig. 74: Removing The Direct & Forward Clutch

31. Second coast brake band:

1. Remove the E-ring and pin.
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Fig. 75: Removing The E-Ring & Pin

2. Remove the second coast brake band.
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Fig. 76: Removing The Second Coast Brake Band

32. Front planetary ring gear:

1. Remove the race.
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Fig. 77: Removing The Race

2. Remove the front planetary ring gear.
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Fig. 78: Removing The Front Planetary Ring Gear

33. Front planetary gear:

1. Remove the race.
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Fig. 79: Removing The Race

2. Remove the front planetary gear.
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Fig. 80: Removing The Front Planetary Gear

34. Remove the sun gear input drum and the one way clutch.
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Fig. 81: Removing The Sun Gear Input Drum & The One Way Clutch
35. Using the thickness gauge, measure the clearance between the second brake snap ring and the flange.
Standard value: 0.62-1.98 mm (0.024-0.078 in.)
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Fig. 82: Measuring The Clearance Between The Second Brake Snap Ring & The Flange
36. Flange, plate, disc:

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2. Remove the flange (1), discs (4) and plates (4).
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Fig. 84: Removing The Flange Discs And Plates

37. Using the micrometer, measure the thickness of disc.
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Fig. 85: Measuring The Thickness Of Disc

38. Parking lock rod:

1. Remove the parking lock pawl bracket.
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Fig. 86: Removing The Parking Lock Pawl Bracket

2. Remove the parking lock rod from the manual valve lever.
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Fig. 87: Removing The Parking Lock Rod From The Manual Valve Lever
39. Remove the parking lock pawl and shaft.
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Fig. 88: Removing The Parking Lock Pawl & Shaft

40. Measure the clearance between the plate and the second brake drum.
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Fig. 89: Measuring The Clearance Between The Plate And The Second Brake Drum
41. Remove the second brake piston sleeve.
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Fig. 90: Removing The Second Brake Piston Sleeve

42. Rear planetary, second brake drum:

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2. Remove the rear planetary gear, the second brake drum and the output shaft.
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Fig. 92: Removing The Rear Planetary Gear, The Second Brake Drum & The Output Shaft
43. Using the screw driver, remove the gasket.
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Fig. 93: Removing The Brake Drum Gasket

REASSEMBLY
1. Install the rear planetary gear, the second brake drum and the output shaft.
1. Install the bearing and race.
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Fig. 94: Installing The Bearing & Race

2. Install the second brake drum, flange, disc and plate.
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Fig. 95: Installing The Second Brake Drum, Flange, Disc & Plate
3. Align the rear planetary gear, second brake drum and output shaft.
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Fig. 96: Aligning The Rear Planetary Gear, Second Brake Drum & Output Shaft
4. Install the snap ring.
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Fig. 97: Installing The Snap Ring

2. Measure the clearance between the plate and the second brake drum.
Clearance: 0.6-0.9 mm (0.024-0.035 in.)
3. Install the second brake piston sleeve.
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Fig. 98: Installing The Second Brake Piston Sleeve

4. Install the brake drum gasket.
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Fig. 99: Installing The Brake Drum Gasket

5. Install the parking lock pawl and shaft.
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Fig. 100: Installing The Parking Lock Pawl & Shaft

6. Install parking lock rod:

1. Connect the parking lock rod to the manual valve lever.
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Fig. 101: Connecting The Parking Lock Rod To The Manual Valve Lever
2. Install the parking lock pawl bracket.
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Fig. 102: Installing The Parking Lock Pawl Bracket

3. Confirm that the planetary ring gear is correctly fixed.
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Fig. 103: Confirming That The Planetary Ring Gear Is Correctly Fixed
7. Install the one-way clutch.
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Fig. 104: Installing The One-Way Clutch

8. Install flange, disc, plate:

1. Install the plate with the rounded edge side of the plate facing the disc.
2. Alternately install discs and plates (Disc first)
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Fig. 105: Alternately Installing Discs & Plates

3. Install the flange and snap ring.
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Fig. 106: Installing The Flange & Snap Ring

9. Using the thickness gauge, measure the clearance between snap ring and flange.
Clearance: 0.62-1.98 mm (0.024-0.078 in.)
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Fig. 107: Measuring The Clearance Between Snap Ring & Flange
10. Install the sun gear input drum.
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Fig. 108: Installing The Sun Gear Input Drum

11. Front planetary gear:

1. Install the front planetary gear on the sun gear.
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Fig. 109: Installing The Front Planetary Gear On The Sun Gear
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3. Install the bearing race on the front planetary gear.
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Fig. 111: Installing The Bearing Race On The Front Planetary Gear
12. Install second coast brake band:

1. Insert the second coast brake band to the case.
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Fig. 112: Inserting The Second Coast Brake Band To The Case
2. Install the pin through the brake band.
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Fig. 113: Installing The Pin Through The Brake Band

3. Install the E-ring to the pin
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Fig. 114: Installing The E-Ring To The Pin

13. Install the bearing and race onto the forward clutch.
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Fig. 115: Installing The Bearing & Race Onto The Forward Clutch
14. Install the race onto the front planetary gear.
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Fig. 116: Installing The Race Onto The Front Planetary Gear
15. Install the forward clutch onto the front planetary ring gear.
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Fig. 117: Installing The Forward Clutch Onto The Front Planetary Ring Gear
16. Install direct clutch, forward clutch:

1. Install the bearing and race.
Fig. 118: Installing The Bearing & Race

2. Install the direct clutch, the forward clutch and the front ring gear to the case.
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Fig. 119: Installing The Direct Clutch, The Forward Clutch and The Front Ring Gear To The
Case
3. Using the vernier caliper, measure the distance between the sun gear.
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Fig. 120: Measuring The Distance Between The Sun Gear

4. Install the bearing and race onto the forward clutch.
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Fig. 121: Installing The Bearing & Race Onto The Forward Clutch
17. Reassemble the second coast brake piston.
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Fig. 122: Reassembling The Second Coast Brake Piston

18. After installing the piston cover, install the snap ring.
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19. Measure the stroke applying the compressed air.
Stroke: 2.0-3.0 mm (0.079-0.12 in.)
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Fig. 124: Measure The Second Coast Brake Piston Stroke

20. Overdrive support:

1. Install the race onto the overdrive support.
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Fig. 125: Installing The Race Onto The Overdrive Support

2. Aim the bolt and oil holes of the overdrive support toward the valve hole side, and align then with
the bolt hole of the transmission case and insert.
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Fig. 126: Inserting Overdrive Support

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4. Install the bolts (2EA).
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Fig. 128: Installing The Bolts

21. Measure the end-play of the output shaft.
22. Install the flange with the rounded edge side of the flange facing the disc.
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Fig. 129: Installing The Flange

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24. Piston stroke of overdrive brake:

1. Place the dial indicator onto the overdrive brake piston.
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Fig. 131: Measuring Overbrake Piston Stroke

2. Measure the stroke applying and releasing the compressed air.
Piston stroke: 1.40-1.70 mm (0.055-0.067 in.)
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Fig. 132: Applying Air To Measure Stroke

25. Remove flange, plate, disc:

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2. Remove the flanges (2EA), plates (3EA) and discs (4EA).
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Fig. 134: Removing The Flanges, Plates And Discs

26. Overdrive ring gear:

1. Install the bearing and the race onto the overdrive support.
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Fig. 135: Installing The Bearing & The Race Onto The Overdrive Support
2. Install the overdrive planetary ring gear.
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Fig. 136: Installing The Overdrive Planetary Ring Gear

27. Install overdrive planetary gear:

1. Install the bearing and the race onto the planetary ring gear.
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Fig. 137: Installing The Bearing & The Race Onto The Planetary Ring Gear
2. Install the race onto the planetary gear.
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Fig. 138: Installing The Race Onto The Planetary Gear

3. Install the overdrive planetary gear and the direct clutch.
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Fig. 139: Installing The Overdrive Planetary Gear & The Direct Clutch
4. Install the bearing and the race onto the direct clutch.
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Fig. 140: Installing The Bearing & The Race Onto The Direct Clutch
28. Install flange, disc, plate:

1. Install the flange with the rounded edge side of the flange facing the disc.
2. Alternately install discs and plates.
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Fig. 141: Installing The Flange & Discs

3. Install the flange and the snap ring.
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Fig. 142: Installing The Flange & The Snap Ring

29. Install oil pump:

1. Install the race onto the oil pump.
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Fig. 143: Installing The Race Onto The Oil Pump

2. Install the oil pump onto the transmission case.
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Fig. 144: Installing The Oil Pump Onto The Transmission Case
30. Make sure the input shaft rotates smoothly.
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Fig. 145: Confirming Smooth Shaft Movement

31. Check for the sound of operation while injecting compressed air into the oil hole indicated in the figure.
NOTE: When inspecting the OD direct clutch, check with the C0 accumulator
piston hole closed.
If there is no noise, disassemble and check the condition of the parts.
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1. Overdrive direct clutch.

2. Direct clutch.
3. Forward clutch.
4. Overdrive brake.
5. Second coast brake.
6. Second brake.
7. First and reverse brake.
Fig. 146: Checking For Proper Operation

32. Install accumulator piston:

1. Install the accumulator piston.
CAUTION: C0: Overdrive direct clutch

C2: Direct clutch.
B0: Overdrive brake.
B2: Second brake.
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Fig. 147: Installing The Accumulator Piston

33. Install the spring
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Fig. 148: Spring Installation Information (1 Of 2)

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Fig. 149: Spring Installation Information (2 Of 2)

34. Install the check ball body and the spring.
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Fig. 150: Installing The Check Ball Body & The Spring
35. Install valve body:

1. Align the groove of the manual valve to the pin of the lever.
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Fig. 151: Aligning The Groove Of The Manual Valve To The Pin Of The Lever
2. Confirm the spring into the accumulator piston are installed correctly.
3. Install the valve body.
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Fig. 152: Installing The Valve Body

36. Install solenoid connector:

1. Install the stopper plate.
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Fig. 153: Installing The Stopper Plate

2. Connect the solenoid connector.

3. Install the clamp bolt.
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Fig. 154: Installing The Clamp Bolt

37. Install the oil strainer.
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Fig. 155: Installing The Oil Strainer

38. Install the oil pan.
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Fig. 156: Installing The Oil Pan

39. Install rotor sensor:

1. Install the key.
3. Install the spacer and the sensor rotor.
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Fig. 157: Installing The Spacer And The Sensor Rotor

40. Install the extension housing.
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Fig. 158: Installing The Extension Housing

41. Install the transmission housing.
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Fig. 159: Installing The Transmission Housing

42. Install the input speed sensor.
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Fig. 160: Installing The Input Speed Sensor

43. Install the output speed sensor.
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Fig. 161: Installing The Output Speed Sensor

44. Install transaxle range switch:

1. Install the transaxle range switch onto the manual valve shaft and temporarily tighten the adjusting
nut.
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Fig. 162: Installing The Transaxle Range Switch

2. Install the washer and the nut.
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Fig. 163: Installing The Washer And The Nut

45. Tighten the adjusting bolt.
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Fig. 164: Tightening The Adjusting Bolt

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COMPONENT DISASSEMBLY, INSPECTION, REPAIR & REASSEMBLY

LOW REVERSE BRAKE
COMPONENTS
Fig. 165: Illustrating Low Reverse Brake Components

DISASSEMBLY
1. Remove the bearing and the race.
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Fig. 166: Removing The Bearing & The Race

2. Remove the snap ring and the piston return spring.
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Fig. 167: Removing The Snap Ring & The Piston Return Spring
3. Apply the compressed air to the transmission case to remove the No. 2 first reverse brake piston.
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Fig. 168: Removing The No. 2 First Reverse Brake Piston

4. Remove the second brake from the output shaft.
Fig. 169: Removing The Second Brake From The Output Shaft
5. Remove the discs (6EA), plates (6EA) and flange.
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Fig. 170: Removing The Discs, Plates & Flange

INSPECTION
1. Using a micrometer, measure the thickness of the discs.
If the thickness is less than the minimun, replace the disc.
Minimun thickness: 1.51 mm (0.059 in.)
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Fig. 171: Measuring The Thickness Of The Discs

REASSEMBLY
1. Make sure the first and reverse brake piston moves smoothly when applying and releasing the
compressed air into the transmission case.
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Fig. 172: Confirming Smooth Piston Operation

OIL PUMP
COMPONENTS
Fig. 173: Illustrating Oil Pump Components

DISASSEMBLY
1. Remove the oil seal ring.
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Fig. 174: Removing The Oil Seal Ring

2. Remove the stator shaft.
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Fig. 175: Removing The Stator Shaft

3. Remove the driven and the drive gear.
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Fig. 176: Removing The Driven & The Drive Gear

INSPECTION
1. Measure the inner diameter of the oil pump bushing.
Standard value: 38.19 mm (1.504 in.)

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Fig. 177: Measuring The Inner Diameter Of The Oil Pump Bushing
2. Measure the inner diameter of the stator shaft bushing.
Front: 21.58 mm (0.850 in.)
Rear: 27.08 mm (1.066 in.)
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Fig. 178: Measuring The Inner Diameter Of The Stator Shaft Bushing
3. Using a feeler gauge, measure the clearance of the driven gear.
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Fig. 179: Measuring The Clearance Of The Driven Gear

REASSEMBLY
1. Install the driven gear and the drive gear after coating them with ATF.
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Fig. 180: Installing The Driven Gear & The Drive Gear
2. Install the stator shaft to the oil pump.
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Fig. 181: Installing The Stator Shaft To The Oil Pump

3. Install the oil seal ring.
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Fig. 182: Installing The Oil Seal Ring

4. Make sure the drive gear rotates smoothly when installed to the torque converter.
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Fig. 183: Confirming Smooth Drive Gear Operation

ONE WAY CLUTCH
COMPONENTS
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Fig. 184: Illustrating One Way Clutch Operation

DISASSEMBLY
1. Hold the planetary sun gear and turn the brake hub. The brake hub should turn freely clockwise and
should lock counterclockwise.
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Fig. 185: Confirming One Way Clutch Operation

2. Separate the one-way clutch from the brake hub.
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Fig. 186: Separating The One-Way Clutch From The Brake Hub
3. Remove the thrust washer.
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Fig. 187: Removing The Thrust Washer

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6. Remove the sun gear input drum.
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Fig. 190: Removing The Sun Gear Input Drum

7. Remove the snap ring of the planetary sun gear.
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Fig. 191: Removing The Snap Ring Of The Planetary Sun Gear
INSPECTION
1. Using a dial indicator, measure the inner diameter of the planetary sun gear.
Maximum diameter: 27.08 mm (1.066 in.)
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Fig. 192: Measuring The Inner Diameter Of The Planetary Sun Gear
REASSEMBLY
1. Install the one-way clutch and the brake hub.
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Fig. 193: Installing The One-Way Clutch & The Brake Hub
2. Hold the planetary sun gear and turn the hub. The brake hub should turn freely clockwise and should lock
counterclockwise.
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REVERSE & OVERDRIVE CLUTCH
COMPONENTS
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Fig. 195: Illustrating Reverse & Overdrive Clutch Components

DISASSEMBLY
1. Hold the O/D direct clutch drum and turn the input shaft. The input shaft should turn freely clockwise and
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Fig. 196: Confirming Reverse & Overdrive Clutch Operation

2. Remove the overdrive direct clutch from the overdrive planetary gear.
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Fig. 197: Removing The Overdrive Direct Clutch From The Overdrive Planetary Gear
3. Check piston stroke of overdrive direct clutch (C0):

1. Place the oil pump onto the torque converter, and then place the O/D direct clutch assembly onto
the oil pump.
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Fig. 198: Assembling Direct Clutch Assembly

2. Using a dial indicator, measure the overdrive direct clutch piston stroke applying and releasing the
compressed air.
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Fig. 199: Measuring The Overdrive Direct Clutch Piston Stroke

4. Remove the snap ring and the piston return spring.
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Fig. 200: Removing The Snap Ring & The Piston Return Spring
5. Remove the overdrive direct clutch piston.
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Fig. 201: Removing The Overdrive Direct Clutch Piston

6. Remove the bearing and the race from the planetary ring gear.
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Fig. 202: Removing The Bearing & The Race From The Planetary Ring Gear

8. Remove the ring gear flange.

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Fig. 204: Removing The Ring Gear Flange

9. Remove the race from the overdrive planetary gear.
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Fig. 205: Removing The Race From The Overdrive Planetary Gear
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11. Remove the retaining plate.
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Fig. 207: Removing The Retaining Plate

12. Remove the overdrive one-way clutch with the outer race.
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Fig. 208: Removing The Overdrive One-Way Clutch

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14. Remove the one-way clutch.

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Fig. 210: Removing The One-Way Clutch

INSPECTION
1. Using a micrometer, measure the thickness of the disc.
Standard value: 1.84 mm (0.072 in.)
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2. Check piston return spring:
Using calipers, measure the free length of the return spring.
Standard length: 15.8 mm (0.622 in.)
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Fig. 212: Measuring The Free Length Of The Return Spring

3. Check overdrive direct clutch piston:

a. Check that check ball is free by shaking the piston.
b. Check that the valve does not leak by applying low pressure compressed air.
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Fig. 213: Check That The Valve Does Not Leak

4. Check overdrive direct clutch drum bushings:
Using a dial indicator, measure the inside diameter of the clutch drum bushings.
Maximum inside diameter: 27.11 mm (1.067 in.)
If the inside diameter is greater then the maximum, replace the clutch drum.
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2003 Kia Sorento LX
Fig. 214: Measuring The Inside Diameter Of The Clutch Drum Bushings
5. Check overdrive planetary gear bushing:
Using a dial indicator, measure the inside diameter of the planetary gear bushing.
Maximum inside diameter: 11.27 mm (0.444 in.)
If the inside diameter is greater than the maximum, replace the planetary gear.
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2003 Kia Sorento LX
Fig. 215: Measuring The Inside Diameter Of The Planetary Gear Bushing
REASSEMBLY
1. Install the thrust washer to the overdrive planetary gear, facing the grooved side upward.
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Fig. 216: Installing The Thrust Washer To The Overdrive Planetary Gear
2. Install the one-way clutch into the outer race, facing the flanged side of the one-way clutch upward.
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Fig. 217: Installing The One-Way Clutch Into The Outer Race
3. Install overdrive one-way clutch with outer race to overdrive planetary gear.
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Fig. 218: Installing Overdrive One-Way Clutch

4. Install retaining plate.
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Fig. 219: Installing Retaining Plate

5. Install snap ring.

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Fig. 220: Installing Snap Ring

6. Coat the race with petroleum jelly and install it to the planetary gear.
NOTE: Race diameter

Inside diameter: 27.1 mm (1.067 in.)
Outside diameter: 41.8 mm (1.646 in.)
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Fig. 221: Installing Race

7. Install ring gear flange to overdrive planetary ring gear.
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Fig. 222: Installing Ring Gear Flange To Overdrive Planetary Ring Gear
8. Install snap ring.
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Fig. 223: Installing Snap Ring

9. Install race and bearing.
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Fig. 224: Installing Race & Bearing

10. Install the race on the planetary gear.
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Fig. 225: Installing The Race On The Planetary Gear

11. Install the piston return spring.
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Fig. 226: Installing The Piston Return Spring

12. Install the plate and the disc.
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Fig. 227: Installing The Plate & The Disc

13. Install the flange.
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Fig. 228: Installing The Flange

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15. Check piston stroke of the direct clutch piston:

1. Place the oil pump onto the torque converter, and then place the O/D direct clutch assembly onto
the oil pump.
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Fig. 230: Assembling O/D Direct Clutch Assembly

2. Using a dial indicator, measure the overdrive direct clutch piston stroke applying and releasing the
compressed air.
Piston stroke: 1.4-1.7 mm (0.055-0.067 in.)
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2003 Kia Sorento LX
Fig. 231: Measuring The Overdrive Direct Clutch Piston Stroke

16. Install the bearing and the race.
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Fig. 232: Installing The Bearing & The Race

17. Install the direct clutch assembly onto the O/D planetary gear.
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Fig. 233: Installing The Direct Clutch Assembly Onto The O/D Planetary Gear
18. Hold the O/D direct clutch drum and turn the input shaft. The input shaft should turn freely clockwise and
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Fig. 234: Confirming Direct Clutch Assembly Operation

SECOND BRAKE
COMPONENTS
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Fig. 235: Illustrating Second Brake Components

DISASSEMBLY
1. Remove the second brake assembly from the output shaft.
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Fig. 236: Removing The Second Brake Assembly From The Output Shaft
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3. Remove the snap ring, the spring and the piston return spring.
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Fig. 238: Removing The Snap Ring, The Spring & The Piston Return Spring
4. Remove the second brake piston.
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Fig. 239: Removing The Second Brake Piston

INSPECTION
1. Check the free length of the return spring.
Standard length: 19.64 mm (0.773 in.)
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Fig. 240: Measuring Return Spring Free Length

REASSEMBLY
1. Being careful not to damage the O-ring, press in the second brake piston into the second brake drum.
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Fig. 241: Pressing The Second Brake Piston Into The Second Brake Drum
2. Install the return spring, the spring retainer and the snap ring.
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Fig. 242: Installing The Return Spring, The Spring Retainer & The Snap Ring
3. Make sure the second brake piston moves smoothly when applying and releasing the low compressed air
to the second brake drum.
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Fig. 243: Confirming Smooth Brake Piston Operation

4. Install the thrust washer.
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Fig. 244: Installing The Thrust Washer

5. Install the second brake assembly to the output shaft.
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Fig. 245: Installing The Second Brake Assembly To The Output Shaft
DIRECT CLUTCH
COMPONENTS
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Fig. 246: Illustrating Direct Clutch Components

DISASSEMBLY
1. Remove the direct clutch drum from the forward clutch.
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Fig. 247: Removing The Direct Clutch Drum From The Forward Clutch
2. Remove the thrust washer from the direct clutch.
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Fig. 248: Removing The Thrust Washer From The Direct Clutch
FORWARD CLUTCH & FRONT CLUTCH
COMPONENTS
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Fig. 249: Illustrating Forward Clutch & Front Clutch Components

DISASSEMBLY
1. Remove the direct clutch and the forward clutch.
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Fig. 250: Removing The Direct Clutch & The Forward Clutch
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3. Remove the snap ring, the flange, the disc and the plate.
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Fig. 252: Removing The Snap Ring, The Flange, The Disc & The Plate
4. Remove the cushion plate.
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Fig. 253: Removing The Cushion Plate

5. Remove the piston return spring and the snap ring.
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Fig. 254: Removing The Piston Return Spring & The Snap Ring
6. Remove the forward clutch piston.
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Fig. 255: Removing The Forward Clutch Piston

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7. Remove the O-ring from the forward clutch.
Fig. 256: Removing The O-Ring From The Forward Clutch

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INSPECTION
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1. Using a micrometer, measure the thickness of the disc.
Minimum: 1.84 mm (0.072 in.)

2. Measure the free length of the return spring.
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Fig. 260: Measuring The Free Length Of The Return Spring

3. Check that check ball is free by shaking the piston.
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Fig. 261: Checking That Check Ball Is Free By Shaking The Piston
4. Measure the inner diameter of the forward clutch drum bushing.
Maximum I.D: 24.08 mm (0.948 in.)
REASSEMBLY
1. Reassemble the bearing and the race.
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Fig. 262: Reassembling The Bearing & The Race

2. Install the oil seal onto the forward clutch.
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Fig. 263: Installing The Oil Seal Onto The Forward Clutch
3. Install the O-ring on the forward clutch drum and the piston.
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Fig. 264: Installing The O-Ring On The Forward Clutch Drum & The Piston
4. Being careful not to damage the O-rings, press the clutch piston into the forward clutch drum.
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Fig. 265: Pressing The Clutch Piston Into The Forward Clutch Drum
5. Install the piston return spring and the snap ring.
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Fig. 266: Installing The Piston Return Spring & The Snap Ring
6. Install the piston return spring and the snap ring.
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Fig. 267: Installing The Piston Return Spring & The Snap Ring
7. Install the cushion plate.
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Fig. 268: Installing The Cushion Plate

8. Install the disc, the flange and the plate.
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Fig. 269: Installing The Disc, The Flange & The Plate
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10. Install the race and the bearing.
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Fig. 271: Installing The Race & The Bearing

11. Install the direct clutch onto the forward clutch assembly.
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Fig. 272: Installing The Direct Clutch Onto The Forward Clutch Assembly
FRONT PLANETARY GEAR
COMPONENTS
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Fig. 273: Illustrating Front Planetary Gear Components

DISASSEMBLY
1. Remove the bearing and the race from the front planetary ring gear.
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Fig. 274: Removing The Bearing & The Race From The Front Planetary Ring Gear
2. Remove the race from the front planetary gear.
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Fig. 275: Removing The Race From The Front Planetary Gear
3. Turn over the planetary gear and remove the bearing and the race.

INSPECTION
1. Measure the inner diameter of the front planetary ring gear bushing.
Maximum I.D: 24.08 mm (0.948 in.)
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Fig. 277: Measuring The Inner Diameter Of The Front Planetary Ring Gear Bushing
REASSEMBLY
1. Install the race onto the planetary gear.
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Fig. 278: Installing The Race Onto The Planetary Gear

2. Turn over the planetary gear and install the race.
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Fig. 279: Installing The Planetary Gear Race

3. Install the race and the bearing onto the front planetary ring gear.
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Fig. 280: Installing The Race & The Bearing Onto The Front Planetary Ring Gear
4. Turn over the planetary ring gear and install the race.
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Fig. 281: Installing Planetary Ring Gear Race

OVERDRIVE BRAKE
COMPONENTS
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Fig. 282: Illustrating Overdrive Brake Components

DISASSEMBLY
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2. Remove the clutch drum washer.
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Fig. 284: Removing The Clutch Drum Washer

3. Hold the OD brake piston so it is not slanted and apply compressed air into the passage to remove the OD
brake piston.
4. Remove the OD brake piston.
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Fig. 285: Removing The OD Brake Piston


REASSEMBLY
1. Install the oil seal ring.
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Fig. 287: Installing The Oil Seal Ring

2. Install the overdrive brake piston.

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Fig. 288: Installing The Overdrive Brake Piston

3. Install the return spring.
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Fig. 289: Installing The Return Spring

4. Install the clutch drum washer onto the OD support.
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Fig. 290: Installing The Clutch Drum Washer

5. Install the race.
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Fig. 291: Installing The Race

OUTPUT SHAFT
COMPONENTS
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Fig. 292: Illustrating Output Shaft Components

DISASSEMBLY
1. Remove the second brake assembly from the output shaft.
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Fig. 293: Removing The Second Brake Assembly From The Output Shaft
2. Remove the output shaft from the rear planetary gear.
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Fig. 294: Removing The Output Shaft From The Rear Planetary Gear
3. Remove the oil seal from the output shaft.
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Fig. 295: Removing The Oil Seal From The Output Shaft
4. Remove first and reverse brake discs, plates and flange.
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Fig. 296: Removing First & Reverse Brake Discs, Plates & Flange
5. Remove rear planetary gear from rear planetary ring gear.
Fig. 297: Removing Rear Planetary Gear From Rear Planetary Ring Gear
6. Hold the planetary gear and turn the one-way clutch inner race. The one-way clutch inner race should turn
freely counterclockwise and should lock clockwise.
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7. Remove the one-way clutch inner race from the rear planetary gear.
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Fig. 299: Removing The One-Way Clutch Inner Race

8. Remove the snap ring with a screwdriver.
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9. Remove The No. 2 One-Way Clutch With Retainers From The Planetary Gear.
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Fig. 301: Removing The No. 2 One-Way Clutch

10. Remove No. 2 and No. 1 Thrust Washers.
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Fig. 302: Removing No. 2 & No. 1 Thrust Washers

11. Remove races and bearing from rear planetary ring gear.
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Fig. 303: Removing Races & Bearing From Rear Planetary Ring Gear
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13. Remove the ring gear flange.

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Fig. 305: Removing The Ring Gear Flange

REASSEMBLY
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1. Install the race and the bearing.
Fig. 306: Installing The Race & The Bearing

2. Install the No. 2 one-way clutch.
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Fig. 307: Installing The No. 2 One-Way Clutch

AUTOMATIC TRANSAXLE CONTROL SYSTEM

TRANSAXLE RANGE SWITCH
1. Operating inspection
1. Check that the starter turns with the ignition switch at START position and the selector in the "P"
and "N" range only.
2. Check that the back-up (reverse) lights illuminate when shifted to the "R" range with the ignition
switch in the ON position.
3. Check the transaxle range switch if it is not working properly.
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Fig. 308: Range Switch Continuity Chart

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Fig. 309: Range Switch Connector Pinout

2. Adjustment
1. Shift the selector lever to the "N" range.
2. Loosen the transaxle range switch mounting bolts.
3. Disconnect the transaxle range switch connector.
4. Check the continuity of the terminals using ohmmeter.
5. Adjust the switch to the point where there is continuity between the terminals.
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Fig. 310: Adjusting Range Switch Position

SHIFT LEVER
COMPONENTS
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Fig. 311: Illustrating Shift Lever Components

REMOVAL
1. Remove the console upper cover plate.
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Fig. 312: Removing The Console Upper Cover Plate

2. Remove the center console assembly.

3. Remove the control cable, the shift lock cable and key lock cable.
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Fig. 313: Removing The Control Cable, The Shift Lock Cable & Key Lock Cable
4. Disconnect the inhibitor switch indicator connector.

5. Remove the control lever assembly.
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Fig. 314: Removing The Control Lever Assembly

6. Remove the control lever bracket.
INSTALLATION
Installation procedure is reverse of removal procedure.
SHIFT LOCK DEVICE
INSPECTION
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z Check the detent place for wear.

z Check the bushing for wear or damage.
z Check the spring for damage or deterioration.
z Check the pin at the end of the rod assembly for wear.
NOTE: When servicing the shift lock device, follow the service instructions and
procedures described below in order to operate it normally.
INSTALLATION
NOTE: Make sure to move shift lever to position "P" to set key lock cam and p-lock as
figured below.
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Fig. 315: Setting Key Lock Cam & P-Lock (1 Of 2)

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Fig. 316: Setting Key Lock Cam & P-Lock (2 Of 2)

ADJUSTMENT
1. Check that lock cam is located in position.

2. Install shift lock cable in position as figure.
3. Temporarily install shift lock cable to A/T lever assembly. Securely insert cable end into fixing pin of
cam.
4. After checking that a portion of cable end touches cable fixing pin of P-lock cam, fix shift lock cable to
A/T lever.
TESTING
1. When the brake pedal is not depressed, push button of the shift lever at "P" position cannot be operated.
(Shift lever cannot be shifted at the other positions from "P").
Push button can be operated at the other positions except "P".
2. When brake pedal stroke is 30 mm (with shift lever at "P" position), push button should be operated
without catching and shift lever can be shifted smoothly to other from "P".
3. When brake pedal is not depressed, shift lever should be shifted smoothly to "P" position from other
positions.
4. Brake pedal must be operated smoothly without catching at all positions.
5. If shift lever is shifted to "P" position, ignition key must be turned to "LOCK" position smoothly.
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2003 Kia Sorento LX
6. Adjust nut "A" and bolt "B" if necessary.
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2003 Kia Sorento LX

2003 AUTOMATIC TRANSMISSIONS 30-40LEI - Diagnosis & Overhaul

2003 AUTOMATIC TRANSMISSIONS

30-40LEI - Diagnosis & Overhaul

Fig. 1: Transaxle Specifications

Fig. 2: Tightening Torque Specifications

SPECIAL SERVICE TOOLS

Fig. 3: Special Service Tools (1 Of 3)

Fig. 4: Special Service Tools (2 Of 3)

Fig. 5: Special Service Tools (3 Of 3)

AUTOMATIC TRANSMISSION FLUID

NOTE: Place the car on a flat, level surface.

3. Let the engine idle.

NOTE: Determine whether or not the automatic transmission should be disassembled,

If the fluid is muddy and varnished, it indicates burned drive plates.

Fig. 6: Electrical System Diagram

HYDRAULIC CONTROL SYSTEM

Fig. 7: Hydraulic Control System Diagram

and self-diagnosis. So while using self-diagnosis, be careful not to make a mistake.

SELF-DIAGNOSIS USING HI-SCAN

DIAGNOSTIC TROUBLESHOOTING CODE CHART

Fig. 8: Diagnostic Troubleshooting Code Description Chart

z TYPE A: DTC stored on the 1st driving.

Warning lamp (W/L): O/D OFF lamp.

"O" - Supported (To be performed at the dame time as DTC store).

"-" - Not supported.

NOTE: Steps 4 to 5 must be accomplished within 5 seconds.

Fig. 9: Line Pressure Specification Chart

Courtesy of KIA MOTORS AMERICA, INC.

Fig. 10: Line Pressure Test Evaluation

Fig. 11: Stall Test RPM Chart

Fig. 12: Evaluation Of Stall Test

TIME LAG TEST

1. Shift the selector lever from "N" to "D" range.

3. Measure the time lag for "N" to "R": in same manner.

STANDARD TIME LAG

Fig. 13: Standard Time Lag Chart

EVALUATION OF TIME LAG TEST

Fig. 14: Evaluation Of Time Lag Test

TCM INPUT AND OUTPUT TERMINAL VOLTAGE TABLE

Fig. 15: TCM Input & Output Terminal Voltage Table (1 Of 2)

Fig. 16: TCM Input & Output Terminal Voltage Table (2 Of 2)

TCM WIRING DIAGRAM

Fig. 17: TCM Wiring Diagram (1 Of 2)

Fig. 18: TCM Wiring Diagram (1 Of 2)

TESTING & DIAGNOSIS

1. Disconnect the speed sensor connector.

Resistance: 560-680° (20 °C)

Fig. 19: Testing Speed Sensor

1. Disconnect the solenoid valve connector.

Resistance: 1-15 ohm

3. If not corrected, replace the solenoid valve.

Fig. 20: Solenoid Valve Connector Pinout

INSPECTION PROCEDURES FOR DIAGNOSTIC TROUBLE CODE

DTC P0748 PRESSURE SOLENOID

DTC P0707 & P0708: INHIBITOR SWITCH CIRCUIT

Fig. 21: P0707 & P0708 Probable Cause Chart

Fig. 22: P0707 & P0708 Diagnostic Trouble Chart

DTC P0710: TRANSMISSION FLUID TEMPERATURE SENSOR

Fig. 23: P0710 Probable Cause Chart

Fig. 24: P0710 Diagnostic Trouble Chart

DTC P0716 & P0717: INPUT SPEED SENSOR

Fig. 25: P0716 & P0717 Probable Cause Chart