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Kia Sportage: Front Wheel Transfer Assembly: Repair procedures - Transfer Assembly - 4 Wheel Drive (4WD) System - Kia Sportage SL Service & Repair ManualKia Sportage: Front Wheel Transfer Assembly: Repair procedures

Third generation SL (2010–2016) / Kia Sportage SL Service & Repair Manual / 4 Wheel Drive (4WD) System / Transfer Assembly / Front Wheel Transfer Assembly: Repair procedures

Removal
   
It is not recommended to overhaul the transfer assembly because a special three-dimensional measuring instrument is required to determine the sizes of the transfer assembly spacers when disassembling and reassembling the transfer assembly. If putting wrong sized spacers in the transfer assembly, it may cause noise and vibration.So, if inner parts of the transfer assembly need to be replaced, the transfer assembly should be replaced with new one.
1.
Lift up the vehicle.
2.
Remove the propeller shaft bolts.(A-4ea)
Tightening torque :
49.0~68.6N.m (5.0~7.0kgf.m, 36.2~50.6lb-ft)

3.
Remove the right driveshaft (passenger side) from the transfer case. (Refer to "Drive shaft" in DS group)
4.
Remove the roll rod bracket(C) after removing bolt(A,B).
Tightening torque :
(B) 49.0~63.7N.m (5.0~6.5kgf.m, 36.2~47.0lb-ft)
(D) 107.9~127.5N.m (11~13kgf.m, 79.6~94.1lb-ft)

5.
Remove the sub frame. ("Front suspension system" in SS group)
6.
Remove the transfer case up and down mounting bolt (A-4ea, B-1ea).
Tightening torque :
(A, B) 60.8~65.7N.m (6.2~6.7kgf.m, 44.8~48.5lb-ft)

7.
Remove the transfer case (C) with the lever after supporting the transfer case with a jack.
Installation
1.
Installation is the reverse of removal.
   
1)
Be careful not to damage the O-ring (A). If the O-ring is damaged, replace with a new one.
2)
Smear and cover splines (B) with molybdenum type high pressure grease.
TECHLUBE MEGAMAX - ALPHA OR EQUIVALENT

3)
Install the propeller shaft near runout marking (Transfer assembly 1ea(A), propeller shaft 1ea(B)).

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