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
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At replacement of any detail specified in the table provided below, adjust a preliminary tightness of the bearing by a choice and installation of the corresponding adjusting laying.
Primary shaft assembled | Secondary shaft assembled | Differential |
Transmission case
Coupling case
Bearing of primary shaft
Primary shaft | Transmission case
Coupling case
Bearing of a secondary shaft
Secondary shaft
Conducted gear wheel of the 4th transfer | Transmission case
Coupling case
Semi-axial bearing of differential
Crown gear wheel and differential case assembled |
Installation sites of special adaptations
| PERFORMANCE ORDER |
| 1. Establish rings of bearings of primary and secondary shaft in a transmission case (at the removed diafragmenny springs and laying). | | 2. Establish a coupling case on a pendant arm of a transmission and establish in a coupling case a ring of the bearing of differential. Put to a bearing ring a piece of a pipe and in easy blows plant it into place that it contacted with a coupling case. | | 3. Establish rings of bearings in the special adaptation (selector), as is shown in drawing. | | 4. Turn the selector to eliminate a gap shown by an arrow. | | 5. Establish differential assembled in a case of coupling and establish a ring of the bearing and the special adaptation (selector) on differential. Establish assembled selectors for primary and secondary shaft in a coupling case. Establish shaft assembled, as is shown in drawing. | | 6. Establish special adaptations (rasporny plugs) in the positions shown in drawing. | | 7. Establish a case of a transmission and tighten special adaptations (bolts) till the demanded moment. Inhaling moment: 38–51 N • m |
| To plant bearings into place, establish special adaptations (prutka) on a detail (And) and (In) selectors and turn selectors to increase gaps. Then turn special adaptations in an opposite direction while gaps will not disappear. | | 9. Manually expand the selector while it will not cease to turn a hand. | |
| 10. Check, that primary and secondary shaft rotated freely. | | 11. With the help щупа measure a gap on a circle between two half of the special adaptation (selector). | | 12. Take the maximum size and define thickness of demanded laying. Use no more than two laying. | | 13. Establish the special A05 adaptation ОК130 191 on differential. |
| 14. By means of a dinamometrichesky key turn the special adaptation. Make adjustment of the special adaptation (selector) by means of ОК130 191 А03 (prutok), the specified preliminary tightness will not be received yet. Preliminary tightness: 0,5 N • m | | 15. With the help щупа measure a gap on a circle of the special adaptation (selector) between And and Century. | | 16. To the measured gap add 0,15 mm and choose a combination from two laying which thickness is the next to the received value. Use no more than two laying. Example: 0,32 mm
0,32 mm + 0,15 mm = 0,47 mm
The next laying (thicker) to 0,47 mm has thickness of 0,50 mm. Thickness of adjusting laying, mm – 0,1, 0,2, 0,25, 0,30, 0,35, 0,40, 0,45, 0,50, 0,55, 0,60, 0,65 |
| 17. Remove a case of a transmission and the special adaptation. | | 18. Remove selectors, primary shaft in collecting and differential. | | 19. Remove rings of bearings. | |
Adjusting laying of primary shaft
| PERFORMANCE ORDER |
| 1. Subtract from a gap defined in point 11 for primary shaft, thickness of a diafragmenny spring (0,65 mm). | |
2. Define a range of a choice of laying by subtraction of values of a standard gap from result of the previous point. Choose thinner laying in this range to receive a standard gap. Standard gap: 0–0,05 mm
Example:
1,22 mm – 0,65 mm = 0,57 mm
Range of a choice of laying:
(0,57 mm – 0,05 mm) – (0,57 mm – 0 mm) = 0,52 mm – 0,57 mm
Laying: 0,55 mm |
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Adjusting laying of a secondary shaft
| PERFORMANCE ORDER |
| 1. Subtract from a gap defined in point 11 for primary shaft, thickness of a diafragmenny spring (0,65 mm). | |
2. Define a range of a choice of laying by subtraction of values of a standard gap from result of the previous point. Choose thinner laying in this range to receive a standard gap. Standard gap:
0,03–0,08 mm
Example:
1,22 mm – 0,65 mm = 0,57 mm
Range of a choice of laying:
(0,57 mm + 0,03 mm) – (0,57 mm + 0,08 mm = 0,60 mm – 0,65 mm
Laying: 0,60 mm | |
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