Kia Clarus/Credos

1995-2001 of release

Repair and car operation



KIA Klarus
1.1. Periodicity of maintenance
+ 2. FE DOHC engines and Т8 DOHC
+ 3. Greasing system
+ 4. Cooling system
+ 5. Power supply system and release
+ 6. Fuel system
+ 7. Ignition system
+ 8. Coupling
- 9. Mechanical transmission
   9.1. Specifications
   9.2. Check of level of oil
   9.3. Oil replacement
   9.4. Transmission removal
   9.5. Transmission installation
   9.6. General recommendations about transmission dismantling
   9.7. Dismantling, check of a fifth / reverse gear and case
   9.8. Dismantling of knots of a case of coupling and transmission case
   9.9. Replacement of oil consolidation of differential on the car
   9.10. Dismantling of primary shaft of a transmission
   9.11. Dismantling of a secondary shaft of a transmission
   9.12. Check of details of primary and secondary shaft
   9.13. General recommendations about assembly
   9.14. Assembly of a secondary shaft
   9.15. Assembly of primary shaft
   9.16. Assembly, check of a fifth / reverse gear and case
   9.17. Choice of adjusting laying
   9.18. Preliminary tightness of the bearing of differential
   9.19. Adjustment of a preliminary tightness of the bearing
   9.20. Remarks on transmission assembly
   9.21. Differential
   9.22. Gear shifting mechanism
   9.23. Search and elimination of malfunctions
+ 10. АКП G4A–EL
+ 11. АКП 50–40 LE
+ 12. Axes and power shafts
+ 13. Steering
+ 14. Wheels and tires
+ 15. Suspension bracket
+ 16. Body
+ 17. Central air
+ 18. Electric equipment
+ 19. Brake system
+ 20. Electric circuits




9.16. Assembly, check of a fifth / reverse gear and case

GENERAL INFORMATION

Collect a fifth / reverse gear and a case in the sequence given on drawing.

Balance of assembly of a fifth / reverse gear and case

1–draft of management;
2–tip of draft of management;
3–fork of switching of the 1st and 2nd transfers;
4–control lever;
5–blocking coupling;
6–fork of switching of the 3rd and 4th transfers;
7–coupling nave;
8–cracker of a clamp of the synchronizer;
9–the sliding coupling of the synchronizer;
10-spring of a cracker of a clamp of the synchronizer;
11-coupling case;
12-differential assembled;
13-secondary shaft assembled;
14-primary shaft assembled;
15-spring;
16-steel ball;
17-fork of switching and draft of switching assembled;
18-cranked lever assembled;
19-shaft of the cranked lever;
20-pin;
21-tip of draft of switching of the 5th transfer and backing transfer;
22-draft of switching of the 5th transfer and backing transfer;
23-intermediate gear wheel of a backing;
24-shaft of an intermediate gear wheel of a backing;
25-magnet;
26-case assembled;
27-switch of neutral situation;
28-switch of a lamp of a backing;
29-lock bolt, ball and spring;
30-a directing bolt;
31-lock bolt;
32-a conducted gear wheel of the 5th transfer;
33-gear wheel plug;
34-gear wheel of the 5th transfer;
35-ring of the synchronizer of the 5th transfer;
36-nave of the coupling of the 5th transfer and backing transfer assembled;
37-fork of switching of the 5th transfer and backing transfer assembled;
38-a conducted gear wheel of the synchronizer of a backing;
39-ring of the synchronizer of a backing;
40-leading gear wheel of the synchronizer of a backing;
41-lock nut of a secondary shaft;
42-lock nut of primary shaft;
43-back cover.

Primary shaft and secondary shaft assembled


PERFORMANCE ORDER
Establish together primary shaft in collecting and a secondary shaft assembled.

Fork of switching and draft of switching assembled

PERFORMANCE ORDER
1. Include the 2nd transfer and put a fork of switching and draft of switching assembled, as is shown in drawing.
2. Insert a saddle of a spring and a spring into a shaft of the lever of a backing, establish a steel ball and press to it consolidation.
3. Pressing the end of a tip of draft of management to scraper consolidation, press on a tip of draft of management in the arrow direction so that the ball entered into a shaft. It will allow to level this draft with a connecting opening of draft of switching in a coupling case.
4. Establish a holder of a nave of each coupling in neutral situation and slightly knock on draft of switching from above that the steel ball entered into the central flute (one of three flutes in a tip of draft of management).
5. Pull forward that part of a tip of draft of management where the ball that the steel ball entered into a clamp in a flute is located.

The cranked lever in collecting and a shaft of the cranked lever

PERFORMANCE ORDER
1. Establish a new sealing ring on a shaft of the cranked lever.
2. Insert the cranked lever between a lead of the voter and a tip of draft of management and connect a shaft of the cranked lever to the cranked lever.
3. Combine shtiftovy openings of a shaft of the cranked lever and a case of coupling and insert a new pin.

Tip of draft of switching of the 5th transfer / backing and draft of switching of the 5th transfer and backing transfer

PERFORMANCE ORDER
Establish a tip of draft of switching (1) and draft of switching (2) and tighten a bolt of fastening of the coulisse.

Inhaling moment: 11,8–13,7 N • m

Intermediate gear wheel of a backing and shaft of an intermediate gear wheel of a backing


PERFORMANCE ORDER
1. Establish an intermediate gear wheel of a backing and a shaft of an intermediate gear wheel of a backing.
2. Attach a magnet to a coupling case.
3. Combine the end of the blocking coupling with a control lever (on an arrow) and turn a carving opening of a shaft of an intermediate gear wheel of a backing in the direction shown in drawing.

Transmission case assembled

PERFORMANCE ORDER
Apply a thin film hermetic on privalochny surfaces of a case of coupling and a case of a transmission and tighten bolts of fastening of a case the demanded moment.

Inhaling moment: 38–51 N • m


Conducted gear wheel of the 5th transfer

PERFORMANCE ORDER
Establish a conducted gear wheel of the 5th transfer, as is shown in drawing.

Nave of the coupling of the 5th transfer and backing transfer in collecting and a fork of switching of the 5th transfer and backing transfer

PERFORMANCE ORDER
Establish together a nave of the coupling of the 5th transfer and backing transfer in collecting and a fork of switching of the 5th transfer and backing transfer.

Lock nut

PERFORMANCE ORDER
1. Include the 1st transfer.
2. By means of the special tool fix primary shaft.
3. Tighten new lock nuts on primary and secondary shaft.

Inhaling moment: 128–196 N • m

4. To Zakontrita lock nuts.
5. By means of a micrometer measure an axial gap of a gear wheel of the 5th transfer.

Nominal gap: 0,10–0,22 mm

Maximum permissible gap: 0,27 mm
6. If the measured gap does not correspond demanded, disassemble and repeatedly collect a transmission.