2021-2023 Kia AWD Coupling Actuator Assembly TSB

Kia has issued Technical Service Bulletin (TSB) TRA108 to address an inoperative All-Wheel Drive (AWD) system in certain 2021-2023 Kia K5, Sorento, and Sportage models. This condition, often signaled by warning lamps on the instrument cluster, is linked to abnormal wear of the motor brushes within the AWD coupling actuator assembly. If you're experiencing a Kia Sportage AWD coupling fault, this bulletin provides the necessary repair information.

Important Warnings for Owners and Technicians

Kia has provided specific instructions and warnings regarding this TSB:

• "A Technical Service Bulletin is a field fix repair program without customer notification that may be performed during the warranty period. Any dealer requesting to perform this repair outside the warranty period will require DPSM approval."
• "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)."
• "If DTC(s) is/are not stored, then this TSB does not apply."

Symptoms

Owners of affected vehicles may observe the following symptoms:

• An inoperative AWD system, also referred to as a 4WD capability concern.
• Illumination of warning lamps on the instrument cluster.

Fault Codes / DTCs

The presence of specific diagnostic trouble codes (DTCs) confirms this issue. If your vehicle exhibits a Kia Sportage AWD coupling fault, these codes will likely be stored:

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

Diagnosis / Trigger Conditions

Diagnosis for this issue primarily relies on confirming the presence of DTCs P195800 and/or P196000. If these codes are not stored, this TSB does not apply, indicating a different root cause for any AWD system concerns.

Repair Procedure Summary

The repair involves replacing the AWD coupling actuator assembly. Technicians will follow these general steps:

1. Confirm Condition: Verify an inoperative AWD/4WD condition is present with stored DTCs P195800 and/or P196000. If these DTCs are not stored, this TSB does not apply.
2. Disconnect Battery: Disconnect the negative (-) battery terminal.
3. Remove 4WD Coupling Assembly: Remove the 4WD Coupling Assembly by referring to the specific repair procedures in the applicable Shop Manual on KGIS, under the chapter "4 Wheel Drive (4WD) System ← Coupling Assembly ← Direct Electro Hydraulic Actuator Coupling ← Repair procedures." The tightening torque for the bolts is specified as 41.9 - 47.7 lb.ft (58.9 - 64.7 N.m). Only the rear side of the propeller shaft needs to be removed to access the coupling assembly. It is crucial not to tilt the AWD/4WD coupling assembly on its side or remove the actuator while it's still installed on the vehicle, as this can cause existing oil to leak out.
4. Clean Actuator Area: Use an air gun to clean the exterior area of the actuator (labeled 'B' in the document's diagrams) to prevent any dust or debris from entering the coupling assembly before disassembly.
5. Remove Coupling Actuator: Loosen the four bolts to remove the AWD/4WD coupling actuator (B). The coupling assembly (A) should be kept in a vertical position during this step. The tightening torque for the 4WD Coupling Actuator Bolts is 7.2 - 8.6 lb.ft (9.8 - 11.7 N.m). Again, avoid tipping the coupling assembly on its side to prevent oil leakage.
6. Drain Oil: To prevent oil spillage, press down on the air breather valve (C) to drain any accumulated oil back into the coupling assembly (A) housing.
7. Install New Actuator: Install the new actuator (B) onto the coupling assembly (A). Lightly lubricate the O-ring before installation.
8. Reinstall Parts: Reinstall all removed parts in reverse order. When reinstalling the propeller shaft, new mounting bolts (D) must be used; the old propeller shaft mounting bolts should not be reused.
9. Confirm Operation: Confirm normal vehicle operation after the repair is complete.

Required Parts

To perform this repair, the following parts are needed:

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

Warranty Information

This repair falls under Warranty N Code: 112 and C Code: ZZ3. The details for claiming this repair are as follows:

Claim Type	Causal P/N	Repair Description	Labor Op Code	Op Time	Replacement P/N	Quantity
W	47899 4G300	Actuator Assembly Replacement	47801F01	0.7 M/H	49129 L8000 or 11435 10256K	3

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Source: NHTSA TSB TRA108