Drivetrain - Transfer Case Shudder When Cold
Model: Sorento [BL]Group: Automatic Transaxle(52)
Number: KT2008101401
Date: Wednesday, November 05, 2008
Area: N. America
Subject:
2003-2006 Sorento (BL) Torque On Demand (TOD)
Transfer Case - (Trans - 022)
Description
This service bulletin provides information related to replacing the internal transfer case clutch pack assembly and related parts. Some 2003 ~ 2006 MY Sorento vehicles equipped with Torque On Demand (TOD) may experience a light shudder condition (when the vehicle is cold in the AM and/or late PM) during tight parking maneuvers while accelerating. To correct the customer concern, please follow instructions exactly as described in this service information. Do not use Dexron in the transfer case. Use only P/N: UB080 CH031.
Effective Vehicle Information
2003-2006 Sorento (BL) models equipped with with Torque On Demand (TOD).
Parts Information
Clutch Pack Kit (47368 H1000KKT) includes the following:
^ 47368 H1000 - Clutch Pack
^ 47319 H1000 - Snap-ring
^ 47314 H1000 - Seal-Oil (Rear flange seal)
^ 47387 4C000 - Magnetic Drain Plug
^ 47394 H1000 - Hub Flange Retaining Nut
^ Small Tube of RTV Sealant
Service Procedure
1. Disconnect the battery negative battery cable.
2. Raise and properly support the vehicle.
3. Remove the transfer case drain plug and discard.
Drain the transfer case fluid.
a) Use the appropriate electronic service information for transfer case removal.
4. Remove the 30mm rear hub flange retaining nut.
*NOTICE
Use a clean working surface when opening the transfer case assembly to prevent foreign debris from entering which may cause lubrication surface damage and may be subject to warranty chargeback.
Note location of wire harness bracket for re-assembly purposes.
5. Using a 4X4 piece of wood, the transfer case can be serviced as shown on a flat surface.
6. Remove transfer case motor assembly:
a) Loosen and remove the 6 mm bolt on the retaining bracket on the shift motor assembly.
7. Remove the three (3) bolts around the head area of the shift motor.
8. After removing the four (4) retaining bolts, gently pry the motor straight-up from the transfer case.
a) After the motor is removed, clean the RTV from the shift motor mating surfaces.
9. Remove all the torx bolts from the transfer case mating area.
10. Remove the flange washer and O-ring seal.
11. Remove the output shaft flange from the transfer case. Remove rear damper weight if necessary.
12. Gently pry the case halves apart using the designed separation tabs as shown.
13. Carefully lift the case half straight upward to separate the case assembly.
13. (Continued) Case assembly is now separated.
14. Remove the output shaft bearing.
*NOTICE
Note the direction of the bearing.
15. Remove the cam coil housing cover.
16. Remove the cam and three (3) steel balls.
17. Remove the wave-spring.
18. Remove and discard the snap-ring as shown.
19. Lift and remove the clutch pack assembly from the transfer case.
*NOTICE
The armature will need to be transferred to the new replacement clutch pack.
20. Clean the two (2) transfer case mating halve surfaces; keep all RTV debris from entering the case during the cleaning process.
*NOTICE
Do NOT use solvents to clean inside the case; the use of clean shop towels to wipe the debris should be sufficient.
!WARNING
The use of surface conditioning disc can cause oil leaks. The sealing surface must maintain a slight rough sealing surface for the RTV to adhere too. The preferred method is to use slow speed cordless drill with wire wheel attachment. Repeat oil leaks can be subject to warranty charge-backs.
!WARNING
Do NOT use this style surface conditioner, as damage could result.
21. Install the new replacement clutch pack assembly.
This photo shows proper installation.
This photo shows improper installation;
Rotate shaft until proper mesh can occur and drum aligns with gear.
22. Install new replacement snap-ring.
23. Install the wave-spring.
24. Install the cam with three (3) steel balls.
25. Install the cam coil housing and install bearing with notches pointing upward. Spin housing until it rests in the center location.
26. Clean internal oil pump screen and magnet from debris.
*NOTICE
Check the orientation of the Shift Fork to Shift Shaft before installing the case covers. Failure to do so may cause the 4WD low selection to be inoperative.
27. Apply the RTV to the case sealing surface area as shown using a 2.5 ~ 3.0 mm bead; do not use excessive sealant which can block the filter screen causing lack of lubrication. Complete case half assembly.
a) Install the torx bolt retaining the case halves, tighten to 19 ~ 25 ft. lbs. (25.7 ~ 33.8 Nm). Install the electrical harness bracket.
28. The shift motor must be installed in several steps to prevent shift motor bind. Apply RTV to the sealing surface - shift motor to transfer case as shown in Step 9a.
a) Loosen the two nuts on the rear mounting bracket
b) Install the three long bolts in the head area of shift motor, torque to 72 inch lbs. (8 ~ 11 Nm).
c) Install the rear bolt on the mounting bracket, torque to 72 inch lbs. (8 ~ 11 Nm).
d) Install and tighten the two nuts on the shift motor bracket, torque to 72 inch lbs. (8 ~ 11 Nm).
29. Install the remainder of components:
a) Rear output flange
b) Replacement O-ring seal
c) Steel washer
d) New replacement retaining nut.
e) New replacement magnetic drain plug
f) Fill the transfer case with 1.5 qts. of Transfer case oil (Shell Donax TG only) on the bench before installing transfer case into the vehicle.
g) Install the damper weight if removed, torque to 25 ft. lbs. (33 Nm).
30. Tighten the flange retaining nut to 150 ft. lbs. (203 Nm), using SST-K95B- 5009-D (Companion Flange Holder) to hold flange while torquing to specification. Stake the nut to the shaft using a flat chisel.
31. Replace the transfer case to transmission gasket and install transfer case into vehicle.
32. Road test and check 4-wheel drive for proper operation and fluid leaks when complete.
Component Configuration of Clutch Pack
WARRANTY INFORMATION:
Transfer Case Maintenance:
Kia Sorento Transfer Case Fluid Information
Lubricant Type: Shell Donax TG
Fluid Capacity: 1.50 US Quarts (1.42L)
Normal Usage: 22k, 45k, 67k, 90k, needs replacement every 23K miles
Severe usage: 15k, 30k, 45k, 60k, needs replacement every 15K miles
EXPLODED VIEW OF INTERNAL BORG-WARNER TRANSFER CASE COMPONENTS