REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Rio (2000 release)

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Kia
	Rio
		Instructions
		Engines A3E, A5D
		Greasing system
		Cooling
		Fuel system
		Ignition system
		Coupling
		Transmission
			Manual Transmission
				Technical data
				Checking the oil level
				Change of oil
				Replacement of an oil sealing ring
				Removing and installing transmission
				Dismantling, check and transmission assemblage
				Carter couplings and components of the gearbox
				Gearbox output shaft
				The secondary shaft of a transmission
				Selecting shims
				Differential
				The gear change mechanism
			Automatic transmission F4E-K
		Axes and power shafts
		Suspension
		Wheels and tires
		Steering
		Brakes
		Body
		The air conditioning system
		Electrical equipment

printable version

Carter couplings and components of the gearbox

Carter couplings and components of the gearbox BF DOHC

1 - the mechanism of the speedometer;
2 - the shift lever;
3 - a rod of a gear change;
4 - the plate;
5 - an external ring of the bearing;
6 - bell;
7 - stem O-ring gear;
8 - a sealing ring of a primary shaft;

9 - an external ring of the bearing of differential;
10 - a sealing ring of differential;
11 - installation adjustment of a tightness of bearings of differential;
12 - an external ring of the bearing of a secondary shaft;
13 - installation adjustment bearing output shaft;
14 - installation adjustment bearing primary shaft;
15 - connection.

Withdrawal

PERFORMANCE ORDER

	1. Remove the speedometer driven gear.
2. pliers long nose pliers, remove the pin.
	3. After removing the lever with reverse gear shaft pliers long nose pliers, remove the gear lever reverse gear.
	4. Loosen the bolt and remove the lever and a switching rod.
5. Loosen the two screws and remove the baffle and gasket.
A warning If necessary, a screwdriver, remove the outer ring of the bearing of a secondary shaft.
6. Insert a screwdriver into the outer ring of the bearing of a secondary shaft clutch.
7. Remove the outer ring of the bearing.
	8. When lifting the socket and remove the outer ring of the bearing outer ring of the bearing.
	9. Use a screwdriver and a hammer, remove the stem O-ring gear.
A warning When removing the sealing ring does not damage the clutch.
	10. Use a screwdriver to remove a sealing ring of a primary shaft.
11. Use a screwdriver to remove a sealing ring of differential.
12. Install the inside of the outer ring of the bearing of differential stripper OK130 170 012.
	13. Remove the outer ring of the bearing of differential.
	14. After installing the stripper OK130 170 012 in the outer ring of the bearing, remove the differential bearing outer ring and shims out of the socket housing.
	15. Use a screwdriver to remove a sealing ring of differential.

Setting

PERFORMANCE ORDER

A warning Before installing the clutch, adjust the tightness of bearing selection and installation of shims: - Tightness of the input shaft; - Tightness of the output shaft; - Tightness of the differential. After measuring the preload using matched lining both adjusting. Grease adjusting linings and external rings of bearings for gearbox oil.
1. After installing the shim into the slot transmission case set the outer ring of the bearing of a secondary shaft.
A warning Apply oil to the outer surface of the gearbox oil seal ring.
	2. Using a mandrel OK201 170 AA1 establish in a nest the gearbox oil sealing ring of differential.
3. Using a mandrel OK201 170 AA1 establish in a nest clutch oil sealing ring of differential.
A warning Install shim that was selected when adjusting the tightness of bearings of differential. Grease adjusting linings and external rings of bearings for gearbox oil.
	4. After installing the shim into the slot, set the gearbox differential bearing outer ring.
	5. Using a mandrel OK201 170 AA1 establish in a nest clutch outer ring of the bearing.
A warning Apply oil to the outer surface of the gearbox oil seal ring thrust gear.
	6. Install the oil sealing ring.
A warning Apply oil to the gearbox outer ring of the bearing of a secondary shaft.
7. Install the socket and the outer ring of the bearing of a secondary shaft in the clutch housing slot.
8. After you install a new gasket set the plate and fix bolts. Torque: 6,8-9,8 N ??? m
A warning Install a protective cover so that the vent hole is disposed downstream.
	9. Replace the cover on the shift rod.
	10. Install the lever and a switching rod into the clutch housing.
	11. After the installation of the lever and a switching rod tighten the bolt. The inhaling moment: 11,7-13,7 N ??? m
12. Install the speedometer drive shaft and a gear wheel on the hub.
	13. Install new O-ring on the sleeve of the speedometer.
14. Install the speedometer driven gear on the clutch housing and tighten the bolt. Torque: 6,8-9,8 N ??? m

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