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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9.7. Dismantling, check and assembly of a fifth / reverse gear and back cover of BF DOHC

GENERAL INFORMATION

Fifth / reverse gear and back cover of BF DOHC

1–back cover;
2–lock-nut;
3–coupling of the synchronizer of a reverse gear;
4–konusny plug of a reverse gear;
5–a blocking ring of the synchronizer;
6–synchronizer of the 5th transfer;
7–fork of the 5th transfer;
8–gear wheel of the 5th transfer;
9–plug of a gear wheel of the 5th transfer;
10-secondary gear wheel of the 5th transfer;
11-clamp stopper, spring and steel ball;
12-bolt of fastening of a shaft of transfer of a backing;
13-transmission case;
14-shaft of transfer of a backing;

15-intermediate gear wheel of transfer of a backing;
16-control unit;
17-lever of installation of a spring;
18-switching rod 1-ой/the 2nd transfers;
19-switching fork 1-ой/the 2nd transfers;
20-switching rod 5-ой/back transfers;
21-lever of a rod of switching 5-ой/back transfers;
22-switching rod 3-ей/4th transfers;
23-lever of a rod of switching 3-ей/4th transfers;
24-switching fork 3-ей/4th transfers;
25-block of gear wheels of a secondary shaft;
26-block of gear wheels of primary shaft;
27-differential

Prevention

Before assembly clear a transmission case solvent.

Clear all removed details (except tight bearings) and surfaces of consolidation by solvent and dry them the compressed air.

Clear all openings the compressed air and check that they are not polluted.

When using the compressed air for cleaning of channels and openings, use goggles as the taken-off pollution I can cause a damage to health.


Dismantling

PERFORMANCE ORDER
1. Establish a transmission at the stand OK130 990 007 with OK130175011A adapter.
2. Remove the bearing and a fork of switching off of coupling.
3. Remove щуп for measurement of level of oil.
4. Remove the sensor of speed.
5. Remove the switch of a lamp of a backing.
6. Remove a back cover.

Prevention

To remove a back cover, slightly knock on a back cover with a kapron hammer.

Do not use repeatedly unscrewed lock-nut.


7. The adaptation OK201 323 021 block primary shaft of a transmission.
8. At the same time include gear wheels of the 1st and 2nd transfer in order that primary shaft of a transmission was not turned.
9. Unbend fillets of a plate fixing a lock-nut.
10. Unscrew a lock-nut from primary and secondary shaft and remove a konusny ring of a reverse gear and the synchronizer coupling from primary shaft.

Prevention

Do not use the reused cylindrical pin.


11. A thin drift and a hammer beat out a cylindrical pin of a fork of inclusion of the 5th transfer.
12. At the same time, assembled remove a synchronizer ring, a fork of inclusion of the 5th transfer, the sliding coupling of the 5th transfer, blocking ring and the gear wheel coupling.
13. Remove a gear wheel of the 5th transfer from a secondary shaft.
14. Turn out a stopper of a clamp and, using a magnet, remove a spring and a steel ball.
15. Turn out a bolt of fastening of an intermediate shaft of a gear wheel of a reverse gear.
16. Remove a transmission case.

Prevention

For removal of a case of a transmission, slightly knock on it with a kapron hammer.


17. Remove a magnet.
18. Remove an intermediate shaft and a gear wheel of transfer of a backing.
19. Turn out three bolts and remove the control unit.
20. Remove the lever of installation of a spring.
21. Deduce from gearing of a gear wheel of the 1st and 2nd transfers. A thin drift and a hammer beat out a cylindrical pin of a fork of inclusion 1-ой/the 2nd transfers.

Prevention

Do not use the reused cylindrical pin.


22. Remove a rod and a fork 1-ой/the 2nd transfers.
23. A thin drift and a hammer beat out a cylindrical pin of a fork 3-ой/the 4th transfers, remove a fork 3-ой/the 4th transfers and the lever of a rod of switching 3-ей/the 4th transfers.
24. Remove an E-shaped lock ring of fixing of a rod 5-ой/back transfers.
25. A thin drift and a hammer beat out a cylindrical pin of a fork 5-ой/back transfers, remove a fork 5-ой/back transfers and the lever of a rod of switching 5-ой/back transfers.
26. At the same time remove primary and secondary shaft assembled.
27. Remove differential.

Assembly


Prevention

Before installation grease an external ring of the bearing of differential.


PERFORMANCE ORDER
1. Establish differential in a transmission case.

Prevention

Be convinced that did not damage an oil sealing ring at installation of primary shaft.

Before installation grease a working edge of a sealing ring.

Grease the second external ring of the bearing in a transmission case.


2. Establish assembled primary and secondary shaft in a transmission case.
3. Establish a fork 3-ой/the 4th transfers on the sliding coupling 3-ей/of the 4th transfers, then insert a rod 5-ой/back transfers to a fork and establish a pin of fastening of a rod 5-ой/back transfers.

Prevention

At installation use a new cylindrical pin.


4. Combine the lever of a rod of switching 5-ой/back transfers with a rod 5-ой/back transfers and fix a cylindrical pin.
5. After rod installation 3-ей/the 4th transfers to a fork 3-ей/the 4th transfers, establish a fork 3-ей/the 4th transfers to the lever of a rod of switching 3-ей/the 4th transfers.

Prevention

At installation use a new cylindrical pin.


6. Combine the lever of a rod of switching 3-ей/the 4th transfers with a rod and fix a cylindrical pin.
7. Combine a switching rod 3-ей/the 4th transfers with a switching fork 3-ей/the 4th transfers and fix a cylindrical pin.
8. Collect a switching fork 1-ой/the 2nd transfers with the sliding coupling 1-ой/2nd of transfers and establish a rod 1-ой/to the 2nd transfers.

Prevention

At installation use a new cylindrical pin.


9. Combine a switching rod 1-ой/the 2nd transfers with a switching fork 1-ой/the 2nd transfers and fix a cylindrical pin.

Prevention

At installation use a new E-shaped lock ring.


10. Establish an E-shaped lock ring on a rod 5-ой/back transfers.

11. Combine in a projection the backing lever with the rod lever 5-ой/back transfers and establish the backing lever on the coupling case.
12. Establish a new sealing ring on a return shaft of gear shifting.

Prevention

Establish a sealing ring so that it settled down in an external flute.


13. Insert a shaft into the lever of inclusion of a backing.
14. Establish a pin.
15. Establish the lever of a spring and fix bolts.

Inhaling moment: 7,8–11,3 N • m

16. Establish the control unit and fix bolts.

Inhaling moment: 7,8–11,3 N • m


Prevention

At control unit installation, consider length of bolts. (The length of a bolt of A is more than B).


17. Establish an intermediate shaft and a backing gear wheel.
18. Establish a magnet.

Prevention

Clear hermetic from interfaced surfaces of a case of coupling and a transmission.


19. Apply a thin film Threebond 1216T or 1216TB hermetic on interfaced surfaces of a case of coupling and a transmission.
20. Establish a transmission case on a case of coupling and fix bolts.

Inhaling moment: 18,6–25,5 N • m

21. Screw a bolt of fastening of an intermediate shaft of a gear wheel of a reverse gear.

Inhaling moment: 18,6–25,5 N • m


Prevention

As the length of springs of clamps differs from each other, correctly choose and establish springs on the places.

Length of a spring of a clamp: 5-ой/back year it is more than 1-ой/than the 2nd, 3-ей/the 4th transfers.

Put hermetic on a carving of a stopper of a clamp.


22. Establish a steel ball and a spring and screw a clamp stopper.

Inhaling moment: 15-20 N • m

23. Establish a conducted gear wheel of the 5th transfer.

Prevention

As the form of a ring of the synchronizer differs from each other, at assembly it is necessary for considering.
In a ring of the synchronizer of transfer of a backing is available admissions of teeths in three places.

Pay attention to the direction of installation of the plug of a gear wheel of the 5th transfer.
Length: A> B


24. Establish the plug of a gear wheel of the 5th transfer, a gear wheel of the 5th transfer and a synchronizer ring.

Prevention

Establish a lubricant flute of the plug of a gear wheel of the 5th transfer from a gear wheel of the 5th transfer.


25. Establish a fork of the 5th transfer to a flute of the synchronizer of the 5th transfer.

26. Establish the synchronizer.

27. Establish on primary shaft the coupling of the synchronizer and a konusny ring of a reverse gear.

Prevention

At installation use a new cylindrical pin.


28. Fix a fork of the 5th transfer by a cylindrical pin.
29. At the same time include gear wheels of the 1st and 2nd transfer in order that primary shaft of a transmission was not turned.
30. The adaptation OK201 323 021 block primary shaft of a transmission.

Prevention

At installation use a new lock-nut.


31. Tighten a lock-nut and for fixing it from an otvorachivaniye bend fillets of a plate fixing a lock-nut.

Inhaling moment: 127–206 N • m

32. By the indicator of hour type measure люфт gear wheels of the 5th transfer and the konusny plug of a backing.

Люфт:
Gear wheels of the 5th transfer: 0,07–0,39 mm
Konusna of the backing plug: 0,1–0,25 mm


If люфт exceeds admissible limits, repeatedly disassemble and collect a transmission.


Prevention

Clear hermetic from interfaced surfaces of a back cover and a transmission case.


33. Apply a thin film Threebond 1216T or 1216TB hermetic on interfaced surfaces of a case of a transmission and a back cover.
34. Establish a back cover taking into account the provision of deepening for the konusny plug of a backing and fix bolts.

Inhaling moment: 7,8–11,3 N • m

35. To Ustanovimta a washer on the switch of a lamp of a backing also screw the switch.

Inhaling moment: 20–24,5 N • m

36. Establish the sensor of speed to the conducted mechanism of a speedometer.

Inhaling moment: 7,8–11,3 N • m

37. Establish the plug on draft of gear shifting.
38. Establish the bearing and a fork of switching off of coupling.
39. Remove a transmission from the stand OK130 990 007 with OK130175011A adapter.