2021-2024 Kia AWD Coupling Actuator Replacement TSB

Kia has issued Technical Service Bulletin (TSB) TRA108 (Rev 1) to address an issue with the 4WD coupling actuator assembly in various 2021-2024 Kia models. This bulletin provides information for technicians to inspect and, if necessary, replace the AWD coupling actuator assembly.

The TSB specifically targets vehicles that may experience an inoperative AWD system, which is also referred to as a 4WD capability concern. This condition is often linked to abnormal wear of the motor brushes located inside the actuator assembly, leading to a Kia 4WD coupling actuator fault.

Symptoms

Owners of affected 2021-2024 Kia vehicles may notice their All-Wheel Drive (AWD) system is not functioning correctly. This inoperative AWD condition can trigger warning lamps to illuminate on the instrument cluster.

These visual warnings indicate a potential issue with the vehicle's 4WD system, often accompanied by specific diagnostic trouble codes (DTCs) stored in the vehicle's computer. If you experience an inoperative AWD system or warning lights, it could indicate a Kia 4WD coupling actuator fault.

Fault Codes / DTCs

When the 4WD coupling actuator assembly experiences abnormal wear, it can lead to the storage of specific Diagnostic Trouble Codes (DTCs) in the vehicle's system. These codes help technicians pinpoint the nature of the Kia 4WD coupling actuator fault.

Code	Description
P195800	4WD Torque Error
P196000	4WD Bleeding Pressure Error

Diagnosis / Trigger Conditions

To properly diagnose the Kia 4WD coupling actuator fault, technicians must confirm the presence of an inoperative AWD/4WD condition along with stored DTCs P195800 and/or P196000. The TSB explicitly states that if these specific DTCs are not stored, this bulletin does not apply to the vehicle's condition.

Important Warnings

Kia has provided critical instructions for technicians to ensure proper repair and prevent further issues:

• "If DTC(s) is/are not stored, then this TSB does not apply."
• "DO NOT tilt the AWD/4WD coupling assembly on its side or remove the actuator with the coupling assembly installed on the vehicle as the existing oil may leak out."
• "DO NOT reuse the 'old' removed propeller shaft mounting bolts (D)."

Repair Procedure Summary

The repair procedure outlined in TSB TRA108 (Rev 1) involves replacing the 4WD coupling actuator assembly. The steps are designed to ensure a precise and effective repair:

1. Confirm DTCs: Verify that DTCs P195800 and/or P196000 are present, indicating a Kia 4WD coupling actuator fault.
2. Disconnect Battery: Disconnect the negative battery terminal for safety.
3. Remove Coupling Assembly: The 4WD Coupling Assembly is removed. Technicians are advised that only the rear side of the propeller shaft needs to be removed to facilitate this. The tightening torque for the coupling assembly bolts is 41.9 - 47.7 lb.ft (58.9 - 64.7 N.m).
4. Clean Actuator Area: Use an air gun to clean the exterior area of the actuator to prevent any dust or debris from entering the coupling assembly during disassembly.
5. Remove Actuator: Loosen the four bolts securing the AWD/4WD coupling actuator. It is crucial to keep the entire coupling assembly in a vertical position during this step to prevent oil leakage. The tightening torque for these actuator bolts is 7.2 - 8.6 lb.ft (9.8 - 11.7 N.m).
6. Drain Oil: To avoid oil spillage, press down on the air breather valve to drain accumulated oil back into the coupling assembly housing.
7. Install New Actuator: Install the new actuator onto the coupling assembly. The O-ring should be lightly lubricated prior to installation.
8. Reinstall Components: Reinstall all removed parts in reverse order. It is essential to use new propeller shaft mounting bolts during this step.
9. Confirm Operation: After reassembly, confirm that the vehicle's 4WD system operates normally.

Required Tools or Parts

To perform this repair, specific parts are required:

• Actuator Assembly: Part Number 47899 4G300 (Quantity: 1)
• Propeller Shaft Mounting Bolts:
  • For NQ5, NQ5 P/HEV models: Part Number 49129 L8000 (Quantity: 3)
  • For DL3, NQ5a, MQ4a, MQ4 P/HEV models: Part Number 11435 10256K (Quantity: 3)

Owner Action

If you own a 2021-2024 Kia K5, Sorento, or Sportage and experience an inoperative AWD system, illuminated warning lights, or suspect a Kia 4WD coupling actuator fault, you should contact your authorized Kia dealer. This is a field fix repair program that may be performed during the warranty period. Any repairs performed outside the warranty period will require DPSM approval.

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Source: NHTSA ID 10253812