Kia Carnival / Sedona factory workshop and repair manual download

Tools & supplies
- Basic hand tools: metric socket set (6–19 mm), ratchet, extensions, combination wrenches
- Torque wrench (0–150 Nm)
- Snap‑ring pliers (internal/external)
- Punches and brass/nylon drift, soft‑face mallet
- Bearing puller / hydraulic press (for pressed bushings/bearings)
- Screwdrivers, picks
- Pry bars, seal puller
- Transmission jack or heavy duty floor jack + wood blocks
- Engine support/cradle or engine hoist (if required)
- Clean bench, parts trays, marker/labels, camera for reference photos
- Parts cleaner / brake cleaner, lint‑free rags
- Gasket maker or new case gasket, RTV as specified
- New transmission gear oil
- Replacement parts: shift drum (assembly) if scored/cracked, shift forks (or fork pads/inserts), shift fork pins, detent balls & springs, circlips, bearings/bushings, seals, case bolts as recommended
- Safety PPE: gloves, eye protection

Safety & prep
1. Work on a level surface. Use jack stands or lift; never rely on a jack alone.
2. Disconnect battery negative terminal.
3. Drain trans oil into a suitable container. Dispose/ recycle properly.
4. Support engine if removing transaxle (engine cradle/hoist) to prevent movement.
5. Use a transmission jack to support the gearbox when freeing mounts/bolts.
6. Clean work area, keep small parts organized, photograph linkages/cables before removing.

Step‑by‑step procedure (manual transaxle shift drum)
Note: This is a general procedure — always consult the factory service manual for model/year‑specific details and torque specs.

A. Remove transaxle from vehicle
1. Raise vehicle, support on stands. Remove front wheels.
2. Remove driveshaft/CV axles from transaxle (unclip outer CV shafts from hubs; mark orientation). Use a pry carefully on inner CV joint to withdraw from trans.
3. Disconnect shift linkage/selector cables from shifter/selector arm — take reference photos.
4. Remove starter, any crossmember, heat shields, exhaust components as required to access transmission.
5. Support transmission with trans jack. Remove transmission mount(s) and bellhousing bolts to engine (keep an assistant/hoist supporting engine if needed). Lower gearbox and move to bench.

B. Transmission case opening
1. Work on a clean bench. Remove any external sensors, covers and the top/bottom case bolts in a pattern to avoid warping.
2. Gently separate case halves. Use soft mallet and pry carefully — avoid gouging mating surfaces.
3. Keep the two halves aligned and supported; note dowels and orientation.

C. Access shift drum assembly
1. Locate the shift drum, selector forks, selector rods and detent assembly.
2. Photograph assembly for reinstallation reference. Note the drum indexing orientation (align to neutral detent).
3. Remove detent springs, balls and any retaining plates carefully — small springs/balls can fly out.
4. Remove circlips/retaining pins that hold selector forks/shafts. Use snap‑ring pliers and drifts as required.
5. Slide selector rods/forks out. Withdraw the shift drum by rotating to the proper index position and sliding it out of the case. If stuck, check for hidden screws/retainers and remove them; don’t force and fracture case.

D. Inspection & decision
1. Inspect shift drum surface (bearing journals and guide grooves) for: deep grooves, pitting, cracks, scored surfaces, or excessive wear.
2. Inspect shift fork contact areas and fork pads for wear/gouging. Check fork pins and rollers for play.
3. Inspect detent balls and spring tension. Inspect bearings/bushings at drum journals.
4. If the drum has deep grooves, cracks or ovalized journals it must be replaced. Light wear may be serviceable with new bushings/bearings but beware of further wear.
5. Replace shift forks that are bent, cracked or have worn contact surfaces beyond service limits. Replace fork pads/inserts if worn.

E. Component removal (if refurbishing)
1. Use a press or bearing puller to remove worn bushings/bearings from drums/shafts. Protect the aluminium case by supporting pressed parts.
2. If replacing fork pads, press out old inserts and install new ones per instructions.
3. Clean all parts with parts cleaner and dry thoroughly.

F. Reassembly (bench)
1. Install new bearings/bushings into case/drum using a press or driven installation tools sized to press on the outer race only. Do not press on the inner race of a bearing.
2. Place the shift drum into position, aligning indexing grooves to neutral position. Make sure the drum rotates freely but without excessive play.
3. Install selector forks on the corresponding shafts/rods in their original locations — forks are usually specific to positions; use photographs as reference.
4. Insert selector rods, secure with pins/circlips. Ensure forks engage drum grooves smoothly and the forks slide without binding.
5. Install detent balls and springs, then retaining plate. Confirm the drum indexes positively through all gear positions; you should feel detent notches.
6. Replace any seals/gaskets or apply new RTV as per FSM. Torque case bolts to factory specs in proper sequence.
7. Reinstall any external pieces removed earlier.

G. Reinstall transmission
1. Refit trans to vehicle with transmission jack; align bellhousing with engine and tighten bolts to torque specs.
2. Reconnect linkage, cables, starter, mounts, driveshaft/CV axles and exhaust/crossmembers removed earlier.
3. Refill trans with correct grade and amount of gear oil.
4. Adjust shift linkage if required per factory procedure. Verify neutral position and full gear engagement with engine off.
5. Lower vehicle, reconnect battery.

H. Test & break‑in
1. Start engine and test gear selection; check for abnormal noises.
2. Road test at low speeds, cycling through all gears. Recheck fluid level after warm up.
3. Re‑inspect for leaks and re-torque if required.

How each tool is used (key ones)
- Transmission jack: supports gearbox during removal/installation; use straps to secure trans to jack saddle.
- Snap‑ring pliers: compress internal/external circlips to remove/install rings without damaging grooves.
- Press / bearing puller: press out/in bearings and bushings evenly; always support surrounding aluminum to avoid distortion.
- Brass/nylon drift and soft mallet: tap pins and light components without damaging surfaces.
- Pick & seal puller: remove oil seals without nicking bores.
- Torque wrench: final tightening to correct torque to avoid stripped threads or crushed aluminium.

Common pitfalls & how to avoid them
- Losing detent balls/springs: remove slowly and cover opening; keep small parts in labeled trays.
- Mixing up fork positions: mark parts and take photos before removal; forks are often not interchangeable.
- Forcing the drum out/in: ensure all retaining hardware removed and drum rotated to index; forcing can damage case or drum.
- Reusing worn drum or forks: minor wear may be acceptable but deep grooves or cracked drum require replacement—reusing will cause re‑failure quickly.
- Damaging bearing races when pressing: press only on the race being installed/removed; use correct adapters.
- Not replacing seals/gaskets: causes leaks. Always use new gaskets/seals.
- Not checking linkage adjustment: can cause false diagnosis after reassembly — adjust per FSM.
- Over‑tightening bolts into aluminium case: use correct torque and thread lockers if specified.
- Using incorrect oil: use the OEM specified fluid.

Replacement parts typically required
- Shift drum assembly (if worn/cracked)
- Shift forks or fork pad/inserts (if worn)
- Detent balls & springs (cheap insurance)
- Case gaskets/seals, input/output shaft seals
- Bearings/bushings at drum journals and selector shafts (if worn)
- Circlips/pins as needed
- Transmission fluid

Final notes
- Always confirm part numbers and torque/clearance specs from the factory service manual for your specific Kia Carnival/Sedona model/year.
- If the drum is cracked or shows heavy wear, replacement drum + new bushings and at least fork pads is recommended — repairs (welding/grinding) are not recommended on precision components.
- Photograph and label everything during disassembly to ensure correct reassembly.
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