KIA Automatic Transmission Program (TRA 007R)

Publication date: 2006-05-01
Reference number: TRA 007R

KIA AUTOMATIC TRANSMISSION PROGRAM

TECHNICAL SERVICE BULLETIN

Reference Number(s): TRA 007r, Date of Issue: May 01, 2006

KIA:	All
GROUP:	Transmission/Driveline

SERVICE INFORMATION

NOTE: This bulletin replaces TSB Transmission/Driveline 003 Revision 3, dated June 2003. Discard all previous TSB Transmission/Driveline 003 issues and revisions.

This bulletin outlines the following updates to the Kia Automatic Transmission Program:

A/T Diagnostic Worksheet
Allowed external repairs (on car repairs)
Changes to diagnostic service procedures
On-line Dealer Communications System (DCS) entry of diagnosis and core information for all Kia automatic transmissions. This process will be used to return ALL A/Ts, regardless of whether they are replaced by a new or remanufactured unit. Failure to return the A/T core will forfeit the warranty claim. See Parts Bulletin 1910-0006 for more information.
NOTE: This Technical Service Bulletin contains many changes to the current Remanufactured Automatic Transmission Program. Failure to comply with the changes could result in charge back of all or portions of OEM or remanufactured A/T claims and/or core credit.

File Under: Transmission/Driveline

ALLOWABLE EXTERNAL REPAIRS

ONLY the following components can be repaired/replaced (if necessary) in the dealership:

PASSENGER CARS

Labor Op

Rio '01-'04

Rio '05-

Optima '02-'06

Optima 2006.5-

Amanti '04-

Sephia '93-'00

Spectra '01-'04

Spectra '04.5-'05 '06-CA

Spectra' '06-Fed

Vehicle Speed Sensor (VSS)

96420R00

YES

Pulse (Sensor) Generator

45644R00

YES

Input Speed Sensor

42620R00

YES

Output Speed Sensor

42621R00

YES

Inhibitor/Range Switch

21440R00

YES

Oil Level Gauge (Dipstick)

46505R00

YES

Oil Cooler Line

YES

ATM Lever (Shift) Cable

43882R00

YES

Shift Lock Cable

43767R00

YES

External A/T Filter⁽¹⁾

Customer Pay

YES

⁽¹⁾	If equipped

TRUCK (MPV)

Part Description

Labor Op

Sedona '02-'05

Sedona '06-

Sorento '02-

Sportage '95-'02

Sportage '05-

Vehicle Speed Sensor (VSS)

96420R00

YES

Pulse (Sensor) Generator

N/A

Input Speed Sensor

42620R00

YES

Output Speed Sensor

42621R00

YES

Inhibitor/Range Switch

21440R00

YES

Oil Level Gauge (Dipstick)

46505R00

YES

Oil Cooler Line

YES

ATM Lever (Shift) Cable

43721R00

YES

Shift Lock Cable

43760R00

YES

External A/T Filter⁽¹⁾

Customer Pay

YES

N/A

⁽¹⁾	If equipped

TSB: Transmission/Driveline 003 (Rev. 4) May 2006

NOTE: Detailed procedures regarding on-line entry to the DCS return entry screen are provided in Kia Parts Bulletin No: 1910-0006 and Kia Warranty Information Communication (KWIC) No. 2006-06.

DIAGNOSIS AND SERVICE PROCEDURES

Open a repair order and with the customer, complete the top section of the A/T Diagnosis Worksheet (WRTY127 - 3/06, available on kdealer.net and KGIS or copy attached form).
Give the repair order and A/T Diagnosis Worksheet to the technician to begin diagnosis of customer concern to determine if there is an internal problem requiring the installation of a remanufactured A/T. The technician should follow the Kia A/T Diagnosis Flow Chart (see attached) and use the Automatic Transmission Tester. Record the results on the A/T Diagnosis Worksheet.
If it is determined that an A/T assembly is necessary, send the RO and A/T Diagnosis Worksheet to the Parts Department to order the correct California or Non-California remanufactured unit for the vehicle. Retain the RO and the A/T Diagnosis Worksheet in Parts Department* . Upon receipt of the remanufactured unit, forward the A/T assembly with the RO and A/T Diagnosis Worksheet to the technician.
*(See Parts Bulletin No. 1910-0006)
- If your dealership resides in the state of California, you must use a "CA" unit regardless of where the vehicle was sold, currently registered, or its emission standard.
- If your dealership resides outside the state of California, use the non-CA remanufactured transmissions, regardless of where the vehicle was sold, currently registered, or its emission standard.
  NOTE: Retain the reusable plastic shipping container and use it to return the removed unit to the Kia Remanufacturing Center. Failure to return the A/T in the authorized shipping container may result in forfeiture of core credit. Refer to Parts Bulletin 1910-0006.
A plastic document bag is included with each remanufactured unit.
Complete all necessary fields on the A/T Diagnosis Worksheet.
Completely drain the transmission unit of Automatic Transmission Fluid (ATF) prior to removing it from the vehicle.
Remove the Automatic Transmission per the Service Manual.
Flush the transmission oil cooler using the aerosol can of Kia Transmission Cooler Flush (P/N: UM990 CH001) that is supplied with the remanufactured unit (refer to detailed instructions in this TSB).
ALL MODELS:

Transfer the vehicle speed sensor, fill tube, etc., as required. Install the remanufactured unit according to the appropriate Service Manual instructions. Fill the remanufactured unit with the correct, Kia Automatic Transmission Fluid. Ordering information can be found in the kdealer.net Parts, Programs & Incentives section.

NOTE: When verifying the repair, especially when the A/T has been replaced, it is critical the A/T has the correct amount of ATF. Confirm with the service information (KGIS) that:

The ATF is at normal operating temperature,
The vehicle itself is level,
Shift selector lever has moved through all gear positions
A/T is in the proper gear selection (Park or neutral) for checking ATF level.
ATF level is at the correct mark on the dip-stick (gauge) indicating A/T is properly filled with ATF.

NOTE: Some models are particularly challenging to determine proper ATF level, i.e., 2002 - 2005 Sedona. Pay extra attention to detail in confirming the proper ATF level on such models. Refer to service information for details.

AUTOMATIC TRANSMISSION FLUID SPECIFICATIONS

Vehicle Type	ATF Type	Part Number
Front wheel drive (ALL)	SP-III	UM010 CH002
Rear wheel drive (except Sorento 5-speed A/T)	Dextron III	Obtain locally
Sorento 5-speed A/T	Kia RED-1	UM040 CH020

NOTE: ATF cannot be ordered via DCS. Ordering information can be found online at www.kiachemicals.com.
Use of incorrect A/T fluid can result in damage to the transmission, which is not covered by Warranty.

SEPHIA/SPECTRA:

Transfer the vehicle speed sensor, fill tube, bracket, and mount (1995-1997MY) from the removed unit to the remanufactured unit. The cooler pipe that bolts to the rear of the transmission has been deleted on P/N: RK2A6 19090. The cooler pipe must be transferred from the removed unit to the remanufactured unit using the new copper sealing washers supplied with the remanufactured unit. For additional information, see Technical Service Bulletin, Transmission/Driveline 006.

NOTE: When adding ATF, allow sufficient time for all air to be purged from the transmission and cooler. With engine idling, move the gear selector through all ranges, and check fluid level with selector in NEUTRAL position. Run vehicle on lift and ensure fluid level before proceeding to road test. The fluid level must be re-checked and adjusted after performing a thorough test drive.

Secure the removed torque converter to the removed transmission using the hold-down bracket and bolt supplied with the remanufactured unit. Install all plastic/rubber plugs and two (2) plastic side gear retainers removed from the remanufactured unit into the removed unit before packaging to prevent ATF leaks and side gears from falling out of position. Record the serial number of the removed unit on the A/T Diagnosis Worksheet. Place the removed unit in the plastic shipping container.
Enter all information from the A/T Diagnosis Worksheet into the DCS Dealer Parts Core Return Entry screens (see Parts Bulletin No: 1910-0006) and print the transmission ATM Core Return Form. Place the following documents into the plastic document bag, provided with the remanufactured transmission.
- Kia transmission ATM Core Return Form (Printed from DCS)
- Kia A/T Diagnosis Worksheet (WRTY 127-03/06)
- Copy of Repair Order (RO) with Technician's notes
Securely close the bag and place inside of the A/T shipping container. Secure lid with retaining straps.
Arrange shipment of the removed transmission in accordance with instructions provided in Parts Bulletin No: 1910-0006.
Applicable core reimbursement will be issued following receipt and inspection of core and ATM Core Return Form.
NOTE: Do not disassemble any part of the removed transmission unit.
NOTE:
KMA may deny/charge back all or portions of OEM or remanufactured A/T claims and/or core credit if:
- A/T cooler is not properly flushed causing the remanufactured unit to fail.
- Remanufactured or OEM unit damaged due to:
  1. Abuse/Accident damage
  2. Improper installation/removal
  3. Improper packaging
  4. Improper diagnosis
  5. Parts missing or damaged
  6. Incorrect ATF
- No trouble found/incorrect diagnosis
- Missing plastic/rubber plugs and retainers
- Missing or incomplete A/T Diagnosis & Shipping Document
- RO missing
- Missing or incomplete Kia A/T Diagnosis Worksheet
For a complete list of core charge debits see Parts Bulletin 1910-0006.
NOTE:
Lost packaging forms or A/T Cooler Flush must be ordered at the dealer's expense:
- Lost Packaging - including the Kia authorized Returnable Container - Call Parts Hotline at 800-542-5611.
- A/T Diagnosis Worksheet (WRTY 127) download via www.kdealer.net or KGIS
- Lost Cooler Flush - Order P/N UM990 CH001 via DCS Order Entry.

CURRENT A/T PUBLICATIONS

The table below lists the Service Publications applicable to diagnosis and repair of A/T - related conditions at time of publication. Refer to KGIS for the latest A/T related service publications.

CURRENT A/T PUBLICATIONS

PUBLICATION	LOCATION	TOPIC
Technical Service Bulletin (TSB)	Vol. 2, Trans/Driveline 007 (2001)	Sephia, Spectra, Rio TCM Logic Revision
Technical Service Bulletin (TSB)	Vol. 3, Trans/Driveline 009 (2002)	Optima A/T 2-3 Shift Flare
Technical Service Bulletin (TSB)	Vol. 3, Trans/Driveline 010 (2004)	2005 MY Sorento 5-Speed A/T
Technical Service Bulletin (TSB)	Vol. 3, Trans/Driveline 012 (2005)	A/T Range Switch - DTC P0705, P0707, P0708
Technical Service Bulletin (TSB)	Vol. 3, Trans/Driveline 013 (2005)	2004MY Spectra 2.0L Low Speed Driveline Bump/Shock
Technical Service Bulletin (TSB)	Trans/Driveline 014 (2006)	2005 MY 2.7L Sportage TCM Reprogramming
Technical Service Bulletin (TSB)	Trans/Driveline 015 (2006)	2005 MY 2.0L Sportage/Spectra TCM Reprogramming
Technical Service Bulletin (TSB)	Trans/Driveline 003 Rev. 4 (2006)	Kia Remanufactured Automatic Transmission Program
Parts Bulletin	No: 1910-0003	Reman A/T Cooler Pipe Deletion
Parts Bulletin	No: 1910-0006	Electronic A/T Core Return System (Rev.) 3/06
Warranty Claim Processing Manual	Chapter 2, Section 2.2	A/T Claim Entry (Pre-Claim)
Technician Times	Vol. 6, Issue 1 (2003)	Adding Fluid to Sedona A/T
Technician Times	Vol. 6, Issue 2 (2003)	Optima/Sedona A/T Diagnosis
Technician Times	Vol. 6, Issue 5 (2003)	External Filters for Optima A/T Units
Technician Times	Vol. 7, Issue 1 (2004)	Proper Installation of A/T Replacement Units
Technician Times	Vol. 7, Issue 5 (2005)	Transaxle Tester Connection
Technician Times	Vol. 7, Issue 5 (2005)	A/T Removal and Test Port Leaks
Technician Times	Vol. 7, Issue 5 (2005)	TechLine FAQ 2004 Spectra 1.8L ATM Shifting
Technician Times	Vol. 9, Issue 1 (2006)	Resetting A/T Adaptive Values

AUTOMATIC TRANSMISSION COOLER FLUSHING

WARNING:

Wear safety glasses and gloves when flushing.
Wear long sleeves and long pants.
Use aerosol flush product with adequate ventilation, preferably in an open-air environment.
Avoid contact with eyes and skin.
Do not breathe vapors or mist.
Keep away from sources of ignition.
Wash hands after using and handling and before eating.
Refer to and follow the Material Safety Data Sheets for Kia SP III Automatic Transmission Fluid (P/N: UM010 CH002) Kia RED-1 Automatic Transmission Fluid (P/N: UM040 CH020) and for Kia Transmission Cooler Flush (P/N: UM990 CH001), provided at www.kiachemicals.com.
Failure to follow these warnings can lead to personal injury or, in cases of extreme exposure, death.

Whenever an automatic transmission is replaced, the cooler must be flushed to remove contaminants such as metal particles or clutch friction material. Improper flushing or the lack of flushing may result in severe damage to the replacement transmission.

After removing the A/T from the vehicle, locate the A/T cooler outlet hose (refer to Kia service information).
Insert the nozzle of the Kia Transmission Cooler Flush into the A/T cooler outlet hose and secure with the metal spring clamp. Place a waste container under the other hose (A/T cooler inlet hose).
NOTE: If necessary, temporarily substitute a screw-type hose clamp to securely attach the cooler hose to the nozzle on cooler flush can (also applies to Step No. 4).
Hold transmission cooler flush can upright, remove protective flip-up cap and press button to release the flushing fluid. Continue to hold the button until clear liquid comes out of the cooler inlet hose.
Reverse the hoses and flush the cooler in the other direction until clear liquid comes out of the cooler outlet hose. Use the entire contents of the can to ensure thorough A/T cooler flushing.
Clear liquid must flow freely in both directions through the A/T cooler. If not, the A/T cooler is restricted and the radiator or A/T cooler assembly must be replaced.
After all of the flushing fluid is used, turn the can upside down and blow any remaining liquid out of the A/T cooler with transmission cooler flush propellant. After disconnecting the transmission cooler flush can, blow shop air (approximately 90 psi) through the cooler (in both directions) to dry it out.
CAUTION: Dispose of the A/T cooler flush waste solution and can in compliance with local state and federal regulations. DO NOT ship the aerosol flush can back to the remanufacturing center.