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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9.8. Dismantling, check and assembly of a fifth / reverse gear and back cover of TE DOHC

GENERAL INFORMATION

Fifth / reverse gear and back cover of TE 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–rasporny plug;
7–fork 5-ой/reverse gear;
8–synchronizer 5-ой/of a reverse gear;
9–a blocking ring of the synchronizer of the 5th transfer;
10-leading gear wheel of the 5th transfer;
11-plug of a gear wheel of the 5th transfer;
12-a conducted gear wheel of the 5th transfer;
13-bolt;
14-bolt;
15-clamp stopper, spring and steel ball;
16-switch of a lamp of a backing;
17-transmission case;
18-magnet;
19-intermediate shaft of transfer of a backing;
20-intermediate gear wheel of transfer of a backing;
21-switching rod 3-ей/4th transfers;
22-lever of a rod of switching 5-ой/back transfers;
23-pin;
24-shaft of the lever of switching;
25-switching lever assembled;
26-forks and switching rod;
27-ball clamp;
28-spring;
29-primary shaft;
30-secondary shaft;
31-differential;
32-coupling case;
33-spring of a cracker of a clamp;
34-the sliding coupling of the synchronizer;
35-clamp cracker;
36-nave of the coupling of the synchronizer;
37-switching fork 3-ей/4th transfers;
38-plug;
39-control lever;
40-switching fork 1-ой/the 2nd transfers;
41-rod;
42-rod lever

Repair

PERFORMANCE ORDER
1. Dismantling carry out in the sequence designated by figures in drawing.
2. Check a condition of all details and, if necessary, replace them.
3. Assembly is carried out to sequences of return to removal.
4. Removal and installation of separate details and knots it is provided below.

Check люфта gear wheels of the 5th transfer

PERFORMANCE ORDER

1. By the indicator of hour type measure люфт gear wheels of the 5th transfer.

Nominal люфт: 0,10–0,22 mm
Maximum permissible люфт: 0,27 mm

2. If люфт exceeds maximum permissible value, check surfaces of contact of a gear wheel of the 5th transfer and tighten the plug. If necessary, replace the worn-out and damaged details.

Otvorachivaniye of a lock-nut

PERFORMANCE ORDER
1. Establish a transmission at the stand OK130 990 007 with OK130175011A adapter.
2. The adaptation OK201 323 021 block primary shaft of a transmission.
3. At the same time include gear wheels of the 1st and 2nd transfer in order that primary shaft of a transmission was not turned.
4. Unbend fillets of a plate fixing a lock-nut.
5. Unscrew lock-nuts from primary and secondary shaft.

Removal of forks and gear shifting rod

PERFORMANCE ORDER
1. Combine the plug ends with a control lever (shooter). Turn a rod counter-clockwise.
2. One hand hold forks 1-ой/the 2nd the transfers, the second – forks 3-ей/the 4th transfers and lift them, at the same time moving synchronizers.
3. Lift a rod and remove a ball clamp, at the same time removing a rod from a coupling case.
4. Separate forks and rods from synchronizers.

Installation of primary and secondary shaft

PERFORMANCE ORDER
Establish primary and secondary shaft in a coupling case how it is shown in drawing.

Installation of forks and gear shifting rod
PERFORMANCE ORDER
1. Establish a fork and a gear shifting rod to a gear wheel of the 2nd transfer how it is shown in drawing.
2. Establish a nest of a spring and a spring in a shaft of the lever of a backing, then establish a ball clamp and a flat washer.
3. Establish an end face of the lever of a rod opposite to a ring and insert a rod so that the ball clamp entered into a shaft. It will expose to one line a core with a rod and will combine with an opening of a case of coupling.
4. Establish synchronizers in neutral situation, and from above insert rods so that the ball clamp entered into average deepening.
5. Press a ball so that it accurately entered into average deepening.

Installation of the lever of a rod and rod 5-ой/back transfers

PERFORMANCE ORDER
Establish the lever of a rod (1) and a rod 5-ой/back transfers (2) and fix a bolt.

Inhaling moment: 11,8–13,7 N • m

Installation of an intermediate shaft and backing gear wheel

PERFORMANCE ORDER
1. Establish a gear wheel of a backing and an intermediate shaft of a gear wheel of a backing.
2. Establish a magnet on a coupling case.

3. Combine the end of the plug of the lock with a control lever and with an opening under a bolt of fastening of an intermediate shaft in the direction shown in drawing.

Installation of a case of a transmission

PERFORMANCE ORDER

Apply a thin film hermetic on interfaced surfaces of a case of coupling and a transmission case, establish a case of a transmission and fix bolts.

Inhaling moment: 38-51H • m

Installation of a conducted gear wheel of the 5th transfer

PERFORMANCE ORDER

Establish a conducted gear wheel of the 5th transfer how it is shown in drawing.

Synchronizer and fork installation 5-ой/back transfers

PERFORMANCE ORDER
Establish together the synchronizer and a fork 5-ой/back transfers.

Tightening of lock-nuts

PERFORMANCE ORDER
1. At the same time include gear wheels of the 1st and 2nd transfer in order that primary shaft of a transmission was not turned.
2. The adaptation OK201 323 021 block primary shaft of a transmission.

Prevention

At installation use a new lock-nut.


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

Inhaling moment: 128–196 N • m

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

Nominal люфт: 0,10–0,22 mm
Maximum permissible люфт: 0,27 mm