Transmission repair DIY

[biffidum]

Symptom: whirring, whining noise getting progressively louder over time.
Resolution: replace 4 internal bearings in gear reduction unit.

The most difficult part about repairing the transmission is removal.
Steps:
1) remove, wheels, brakes, lower ball joint and drive shafts (both sides)
2) remove all bolts retaining transmission to electric motor - most difficult is up behind motor and requires a swivel and socket extension
3) split transmission
4) bearings that seem to show wear are input shaft bearings and differential bearings. The intermediate shaft was fine on mine.
5) Use gear puller to remove bearings and pry bars/screwdriver to remove races for differential bearings on axle and casting
6) reassemble with an appropriate sealant
7) fill with oil - I used fancy Royal Purple oil.

Parts:
Input shaft bearings X2 - SKF 6202-2RS1 $50
Differential bearings X2 - SKF 32010 X $50
Seals are available from Kia parts desk $14

NOTE: If your transmission is making loud clunking noises, you likely have a broken differential (using parking brake while car is in motion). The differential is shared with other Kia and Hyundai models and is P/N A6GF1. This can be purchased from transmission suppliers for about $400 or from a wrecker transmission.

I hope to get another 150,000kms out of the car.

 

[JejuSoul]

Brilliant report of your repair. Thanks for posting.

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Some previous info from this site includes this Ukrainian YouTube video



For the previous thread see :- Electronic Parking Brake (EPB) firmware : (November 2023 - another recall)

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Do the parking pawls fail in a way to cause damage to drive unit seals? The answer is yes.
This most commonly happens when drivers put the car into Park before it has fully stopped.
This led to many cars rolling while parked and parking brake recalls.

On the Canadian Motor Vehicle Safety Recalls Database
Under Transport Canada Recall # 2020-310 they state
"On certain vehicles, the transmission could be damaged if the driver shifts to the "P" (Park) position before the vehicle has stopped moving. As a result, the vehicle could move when the shift lever is in the Park position and the parking brake is not used."

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There's a thread from 2016 about self-inflicted gearbox destruction.
This occurs when the gear stick is shifted to park while at speed.
see :- New Transmission on 2016 Soul EV

Moving the gear lever into 'P' while the car is driving risks destroying the transmission.

Pictures by Alkl from the German Forum - Kaputtes Getriebe

Broken holder (top center)


Second gear half with gear wheel for park claw (far right)


Hole in Transmission

 

[biffidum]

Forgot to mention that the seals on the replacement input shaft bearings need to be removed with a pick to ensure they get oiled (cooled) properly.