Kia Sephia/Shuma/Spectra

since 1995 of release

Repair and car operation



KIA of Sefia / Noise/range
+ 2. Engine
+ 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 BF DOHC oil
   9.3. Check of level of TE DOHC oil
   9.4. Oil replacement
   9.5. Replacement of an oil sealing ring
   9.6. Removal and transmission installation
   9.7. Dismantling, check and assembly of a fifth / reverse gear and back cover of BF DOHC
   9.8. Dismantling, check and assembly of a fifth / reverse gear and back cover of TE DOHC
   9.9. Case of coupling and components of a case of a transmission of BF DOHC
   9.10. Case of coupling and components of a case of a transmission of TE DOHC
   9.11. Primary shaft of a transmission of BF DOHC
   9.12. Primary shaft of a transmission of TE DOHC
   9.13. Secondary shaft of a transmission of BF DOHC
   9.14. Secondary shaft of a transmission of TE DOHC
   9.15. Choice of adjusting laying
   9.16. Differential
   9.17. Gear shifting mechanism
+ 10. Automatic transmission
+ 11. Axes and power shafts
+ 12. Steering
+ 13. Wheels and tires
+ 14. Brake system
+ 15. Suspension bracket
+ 16. Body
+ 17. Central air
+ 18. Electric equipment


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9.14. Secondary shaft of a transmission of TE DOHC

GENERAL INFORMATION

Secondary shaft of a transmission of TE DOHC

1–bearing;
2–a conducted gear wheel of the 4th transfer;
3–rasporny plug;
4–gear wheel of the 3rd transfer;
5–gear wheel of the 2nd transfer;
6–ring of the synchronizer of the 2nd transfer;
7–lock ring;
8–synchronizer 1-ой/2nd of transfers;
9–ring of the synchronizer of the 1st transfer;
10-gear wheel of the 1st transfer;
11-bearing;
12-secondary shaft;
13-spring of a cracker of a clamp;
14-the sliding coupling of the synchronizer 1-ой/of the 2nd of transfers;
15-clamp cracker;
16-nave of the coupling of the synchronizer 1-ой/of the 2nd of transfers

Preliminary check

GAP OF THE GEAR WHEEL OF THE 1ST TRANSFER

PERFORMANCE ORDER
1. Measure a gap between a gear wheel of the 1st transfer and a differential gear wheel.

Nominal gap: 0,05–0,28 mm
Maximum permissible gap: 0,33 mm

2. If the gap exceeds maximum permissible value, check a surface of contact of a gear wheel of the 1st transfer, a gear wheel of differential and the coupling of the synchronizer 1-ой/of the 2nd of transfers. Replace the worn-out or damaged details.

GAP OF THE GEAR WHEEL OF THE 2ND TRANSFER

PERFORMANCE ORDER
1. Measure a gap between a gear wheel of the 2nd transfer and a gear wheel of the 3rd transfer.

Nominal gap: 0,18–0,46 mm
Maximum permissible gap: 0,51 mm

2. If the gap exceeds maximum permissible value, check a surface of contact of a gear wheel of the 2nd transfer, a gear wheel of the 3rd transfer and the coupling of the synchronizer 1-ой/of the 2nd of transfers. Replace the worn-out or damaged details.

Dismantling

BEARING AND GEAR WHEEL OF THE 4TH TRANSFER

PERFORMANCE ORDER
Using a press and the special adaptation OK201 172 008, remove a gear wheel of the 4th transfer.

GEAR WHEELS OF THE 2ND AND 3RD TRANSFERS

PERFORMANCE ORDER
1. Remove a lock ring.
2. Move gear wheels to the шестерне1st transfer.
3. Using a press and the special adaptation OK201 172 008, remove a gear wheel of the 2nd and a gear wheel of the 3rd transfer.

THE SYNCHRONIZER 1-ОЙ/2ND OF TRANSFERS, RING OF THE SYNCHRONIZER AND CONDUCTED GEAR WHEEL OF THE 1ST TRANSFER

PERFORMANCE ORDER
1. Remove a lock ring.
2. Using a press, remove the synchronizer 1-ой/2nd of transfers, a ring of the synchronizer and a conducted gear wheel of the 1st transfer

BEARING

PERFORMANCE ORDER


Using a press and the special adaptation OK130 171 013, remove the bearing.

Check

GEAR WHEELS

PERFORMANCE ORDER
1. Examine synchronizer cones on lack of wear.
2. Examine a condition of a surface of teeths of gear wheels on absence of damages, wear and cracks.
3. Visually check a condition of a ring of the synchronizer on absence of damages, wear and cracks.

SYNCHRONIZER RING

PERFORMANCE ORDER

1. Visually check a condition of teeths of a ring of the synchronizer on absence of damages, wear and cracks.

2. Check a condition of a conic surface on absence of damages, wear and cracks.
3. Establish a synchronizer ring in a gear wheel.

4. Measure a gap between a ring of the synchronizer and a surface of a flange of a gear wheel.

Nominal gap: 1,5 mm
Minimum admissible gap: 0,8 mm

SYNCHRONIZER

PERFORMANCE ORDER
1. Visually check a condition of the synchronizer and its working capacity.
2. Visually check a condition of teeths of a ring of the synchronizer on absence of damages, wear and cracks.
3. Check a condition of crackers of a clamp on absence of damages, wear and cracks.
4. Measure a gap between sliding couplings of the synchronizer and forks.
Gap, mm
Element
The nominal
Maximum permissible
1-ая/the 2nd
0,1-0,45
0,95
3-ья/the 4th
0,10-0,40
0,90
5-ая/Z.Kh.
0,10-0,36
0,86

INTERMEDIATE GEAR WHEEL OF THE BACKING

PERFORMANCE ORDER
1. Visually check a condition of teeths of a gear wheel on absence of damages, wear and cracks.
2. Measure a gap between the plug of an intermediate gear wheel of a backing and the lever.

Nominal gap: 0,01–0,32 mm
Minimum admissible gap: 0,5 mm

BEARING

PERFORMANCE ORDER

Check the bearing on absence of damages and smoothness of rotation.

PRIMARY AND SECONDARY SHAFT

PERFORMANCE ORDER
1. Check surfaces of gear wheels contacting to shaft on lack of wear and damages.
2. Check shlitsa of shaft on lack of wear and damages.
3. Visually check a condition of teeths of gear wheels on absence of damages, wear and cracks.
4. Check a channel condition for supply of greasing on lack of a contamination.

5. By the indicator of hour type measure palpation of primary and secondary shaft.

Palpation of primary shaft: 0,05 mm
Palpation of a secondary shaft: 0,015 mm


Prevention

If replacement of a secondary shaft was carried out, adjust a preliminary tightness of the bearing.


 
Oil gap, mm

Element
Shaft (external diameter)
Gear wheel (internal diameter)
Plug (external diameter)
The 1st
39,445-39,470
39,500-39,525
0,03-0,08
The 2nd
34,945-34,970
35,000-35,025
3-ая
35,945-35,970
36,000-36,025
The 4th
30,945-30,970
31,000-31,025
The 5th
34,000-34,025
33,945-33,970

SENSOR OF SPEED (MECHANISM OF THE DRIVE OF THE SPEEDOMETER)

PERFORMANCE ORDER
1. Visually check a condition of teeths on absence of damages, wear and cracks.
2. Check a sealing ring on absence of damages and wear.

Assembly

NAVE OF THE COUPLING OF THE SYNCHRONIZER

PERFORMANCE ORDER
Establish clamp and spring crackers in a nave of the coupling of the synchronizer.

Sizes of a cracker of a clamp, mm

Element
1
2
3
1-ая/the 2nd
19,0
4,25
5,0
3-ья/the 4th
17,0
4,25
5,0
4-ая/Z.Kh.
17,0
4,25
5,0

THE BEARING (FROM DIFFERENTIAL)

PERFORMANCE ORDER

Using a press and the special AA1 adaptation OK900 175, establish the new bearing.

GEAR WHEEL OF THE 1ST TRANSFER, RING OF THE SYNCHRONIZER OF THE 1ST TRANSFER AND SYNCHRONIZER 1-ОЙ/OF THE 2ND TRANSFER


Prevention

On a ring of the synchronizer of the 2nd transfer there are no teeths in three places on perimeter to distinguish it from other rings of the synchronizer.


PERFORMANCE ORDER
1. Establish a gear wheel of the 1st transfer, a ring of the synchronizer of the 1st transfer and the synchronizer 1-ой/of the 2nd transfer how it is shown in drawing.
2. Combine dredging of a ring of the synchronizer with clamp crackers.
3. Using a press and the special AA1 adaptation OK900 175, establish a nave of the coupling of the synchronizer 1-ой/of the 2nd of transfers.

RING OF THE SYNCHRONIZER OF THE 2ND TRANSFER AND GEAR WHEEL OF THE 2ND AND 3RD TRANSFERS

PERFORMANCE ORDER
1. Establish a ring of the synchronizer of the 2nd transfer and a gear wheel of the 2nd transfer.
2. Using a press and the special AA1 adaptation OK900 175, establish a gear wheel of the 3rd transfer.

GEAR WHEEL OF THE 4TH TRANSFER AND INTERNAL RING OF THE BEARING

PERFORMANCE ORDER
1. Using a press and the special AA1 adaptation OK900 175, establish a gear wheel of the 4th transfer and an internal ring of the bearing.
2. Measure a gap between a gear wheel of the 1st transfer and a gear wheel of a drive of differential.

Nominal gap: 0,05-0,28 mm
Maximum permissible gap: 0,33 mm

3. Measure a gap between a gear wheel of the 2nd and 3rd transfers.

Nominal gap: 0,10-0,22 mm
Maximum permissible gap: 0,27 mm

4. If gaps do not correspond demanded, disassemble and repeatedly collect a secondary shaft.