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Discussion Starter · #1 ·
Hi all


The gearbox has failed on my 2004 2.9 diesel Sedona.

The Kia manuals say that the front subframe has to be removed to get the gearbox and/or engine out.



It looks like both can be removed from above through the bonnet.

Has anyone done this?

Is it possible?



Cheers

Pat
 

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First of all, I wouldn't attempt to remove the engine or gearbox "THROUGH THE BONNET" HE HE, Sorry I know what you mean!I have written a thread here regarding changing the clutch in situ. I had to eventually remove the gearbox, but this involved just lowering the subframe at the N/S a bit further.
Have a look at "changing a clutch thread" in the Sedona Forum
 

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Discussion Starter · #3 ·
Hi MININUT, any chance you can point to the thread as the search can't find it even when I just search for your posts.


Cheers

Pat
 

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was looking under the bonnet of mine today checking water and oil etc a little tight but does look possible.

Edited by: dmc
 

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Discussion Starter · #7 ·
And the answer to this is.. I don't know.


After looking further into it and all the pipework etc. that must be removed to get the engine out we didn't even attempt it.



The gearbox came out of the NS wing in the end.
 

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Patman1200 said:
Hi all


The gearbox has failed on my 2004 2.9 diesel Sedona.

The Kia manuals say that the front subframe has to be removed to get the gearbox and/or engine out.



It looks like both can be removed from above through the bonnet.

Has anyone done this?

Is it possible?



Cheers

Pat
Hi Patman

I knew I had seen this question a few months back on the other forum the reply is below from user KIA mad

Engine Out

hi

You can remove a 2.9dti and and I think you have a j3 engine- through the top on its OWN

That said, there is a lot to take off- disconnect.

But changing the engine I expect most bits will go on the donor unit.

Just to give you an idea of what's entailed.

To start- remove the battery, air intake pipe- complete intercooler- air
filter box and front support bracket this gives you access to the gear
box mounting.

Engine cover and top & bottom rad hose

Fuel filter and bracket + fuel lines to pump

Basically any cable or hose connected to the engine from the bay walls

You could also, if you don't mind the extra work, remove the rad/ac rad and the front bonnet slam panel

You will need at least 1.5 ton high lift hoist or other means of lifting
the unit out ( for instance A/ frame and heavy block and tackle) and
good trolley jack and axle stands

Raise car on to stands with the wheels at least 150mm=6" above the ground to allow work underneath

Remove the road wheels- inner wing trim covers- with a piece of board jack up under the sump just to take the weight

Next remove the front top and gearbox mounting

Hang engine on hoist and move the jack to gearbox end with jack handle facing the nearside.

Remove the front exhaust pipe -remove the 2 lower mountings

You will need to get the gearbox over as far as poss and may have to remove the drive shafts

mainly the short part of the offside to allow the gearbox to be pitched up on re-assembly

ease the unit to the nearside between the sub frame and the body box
section ( things to watch out for) avoid putting too much stress on the
gear change cables etc.

remove all bolts joining engine to bell housing and carefully separate the two and lift the engine

at this stage the alternator may come into contact with the servo and
may need to be removed at this point(this just one of many nightmares
as is the steering and ac pumps)

you just have to look out for snags

no doubt I've missed lots of bits but I hope this helps

I feel like a haynes manual!

good luck

regards

kia mad uk
 
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