Transfer case problem - Kia Forum
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#1 (permalink) Old 10-25-2010, 06:58 PM
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Default Transfer case problem

Hi, im new here to the kia forum and looking for some info to repair my wife's 04 sorento AWD. Recently it started dragging/hopping the inside rear tire at low speeds. I assumed the posi unit in the diff was toast, but found the issue seems to be in the T-case. If i unplug one of the main plugs on the t-case the problem goes away but the service 4wd light comes on and the awd does not work. Is there some sort of clutch pack in the transfer case that needs to be replaced? a viscous coupling? Or do i likely have a module/controller bad somewhere applying power when it shouldn't be? I figure im probably going to have to bite the bullet and buy a service manual sooner or later seeing as how the wife wants to keep this thing a while, so if anyone can recommend a good place to buy one that would help also.

01 GMC 2500hd, duramax with some mods

Wife's ride is an 04 sorento EX.
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#2 (permalink) Old 10-26-2010, 08:41 AM
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Sorry, can't help you with T-case, but you don't have to buy manual, register here:
Kia Global Information System (KGIS) ans you'll find service info and a lot more there.
Just make sure you using Internet Explorer browser.
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#3 (permalink) Old 10-27-2010, 04:47 PM
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OK, thanks for the KGIS heads up lots of great reference material. But that didn't really help as the vehicle hasn't tripped any diagnostic codes....... Anyone else know anything about these things? Do i have a wheel speed sensor issue thats not allowing my active torque transfer case to slip when it should?

01 GMC 2500hd, duramax with some mods

Wife's ride is an 04 sorento EX.
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#4 (permalink) Old 10-28-2010, 02:37 AM
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Just a couple of comments for you:
There is a clutch pack, but it operates the torque transfer to front wheels (chain drive and layshaft). The drive to rear wheels is direct. Except, there is a planetary gear system for 4wd Low, but that would affect all wheels. Individual wheel sensors do not control transfer case action. That is by sensors on the front/rear shafts from the transfer case themselves. I can't figure anything that would cause the symptoms you describe related to the transfer case itself, despite they go away when disconnected.
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#5 (permalink) Old 11-04-2010, 10:48 AM
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I had an issue last year with my 03 that sounds similar. Aweful noise when turning, and when I came to a stop, there was a noticable "bang". Kia dealership scammed me into changing out quite a few things that ended up not being covered under warranty. (Tires, front Diff, and a few others)

I took my vehicle to a local transmission/power train establishment. After a 1 day diagnosis, they determined the issue was with the Output Speed Sensor. They stated the dealership should have discovered the faulty sensor immediately.

The faulty sensor was causing the clutch inside the transfer case to engage halfway when turning. Due to the faulty sensor, the computer interpreted the conditions when turning as “slipping”, and tried to engage the clutch to compensate.

It may be the same issue you are having. The sensor ended up being a $120 item. No problems ever since.

Oh yeah...I got all my money back from Kia too as they should have been able to detect the cause.

Good luck!
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#6 (permalink) Old 11-30-2010, 11:25 AM
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Hey, thanks for the heads up. Ill be looking into that.

01 GMC 2500hd, duramax with some mods

Wife's ride is an 04 sorento EX.
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#7 (permalink) Old 01-17-2011, 01:15 PM
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OK, wife is still irked and this thing is still broke, anyone got any ideas? Im about ready to throw an encoder motor in and see what happens.

01 GMC 2500hd, duramax with some mods

Wife's ride is an 04 sorento EX.
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#8 (permalink) Old 03-28-2011, 10:36 AM
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I took the fuse out in the passenger compartment and voila!!! no more problems. We replaced the rear diff and the transfer case , 6 months later we had the same problem it is probably the wheel speed sensor but for now removing the fuse fixed it.
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