Kia Carens. Instruction — part 122

Standard clearance : 0~0.002 in (0~0.05 mm)
Example : 0.048 in (1.22 mm) - 0.026 in (0.065 mm) = 0.022 in (0.57 mm)
Shim selection range : (0.022 in (0.57 mm) - 0.002 in (0.05 mm)) ~ (0.022 in (0.57 mm) - 0 mm (0 in)) =
0.020 in (0.52 mm) ~ 0.022 in (0.57 mm)
Shim : 0.022 in (0.55 mm)

Thickness (Shaft gears)

in(mm)

0.008 (0.20)
0.010 (0.25)
0.012 (0.30)
0.014 (0.35)
0.016 (0.40)
0.018 (0.45)

0.020 (0.50)
0.022 (0.55)
0.024 (0.60)
0.026 (0.65)
0.028 (0.70)

Secondary shaft adjustment shim

• Make shim selection range by adding standard clearance parameters to result in previous step.
• Select thinner shim within range to obtain standard clearance.

Tightening amount : 0.001~0.003 in (0.03~0.08 mm)
Shim selection range : (0.022 in (0.57 mm) + 0.001 in (0.03 mm)) ~ (0.022 in (0.57 mm) + 0.003 in (0.08
mm)) = 0.024 in (0.60 mm) ~0.026 in (0.65mm))
Shim : 0.024 in (0.60 mm)

1. Install SST (0K130 191 A05) to differential.

2. Turn SST (0K130 322 020) with torque wrench. Adjust SST (0K130 175 A03) until specified preload is obtained.

Preload : 12.15 ~ 17.36 lb-in ( 1.37 ~1.96 N·m, 14~20 kg-cm)

3. Measure gap between and around cirumference of SST(0K900 175 A01) by using feeler gauge.

4. Add 0.006 in (0.15 mm) to measured clearance and select combination of two shims closest in value to thatn

measurement, use no more than two shims.

Example : 0.013 in (0.32 mm)
0.013 in (0.32 mm) + 0.006 in (0.15 mm) + 0.019 in (0.47 mm).
Nearest shim (on thick side) to 0.019 in (0.47 mm) is 0.020 in (0.50 mm).

5. Remove transaxle case and SST(0K900 175 AA0)

6. Remove selectors, primary shaft assembly and the differential.

7. Remove bearing races.

Oil seal (differential)

1. Using SST (0K201 170 AA1) and hammer, tap new oil seal in evenly until ST(0K201 170 AA1) contacts transaxle

case.

2. Coat lip of oil seal with transaxle oil

Thickness

in(mm)

0.004(0.10)
0.008(0.20)
0.010(0.25)
0.012(0.30)
0.014(0.35)
0.016(0.40)
0.018(0.45)
0.020(0.50)
0.022(0.55)
0.024(0.60)
0.026(0.65)

0.004(0.10)
0.008(0.20)
0.010(0.25)
0.012(0.30)
0.014(0.35)
0.016(0.40)
0.018(0.45)
0.020(0.50)
0.022(0.55)
0.024(0.60)
0.026(0.65)

Bearing race (differential)

1. Install adjustment shim(s) to differential case.

2. Apply transaxle oil to bearing race, and install it to differential case by using pipe.

Diaphragm spring on primary shaft

1. Install diaphragm spring as shown in figure.

Bearing race (transaxle case)

1. Install adjustment shim(s) to primary and secondary shaft bearing seats in transaxle case.

2. Apply transaxle oil to each bearing race, and install themn to transaxle case by using pipe.

Oil seal(change rod assembly)

1. Install new oil seal by using pipe.

2. Coat lip of oil seal with transaxle oil.

Outer diameter of pipe : 1.02 in (26.0 mm)

Boot

1. Install boot so that drain hole is facing downward when mounted on vehicle.

Oil seal (primary shaft)

1. Apply transaxle oil to outer circumference of oil seal, and install it to transaxle case by using pipe.

Bearing preload

Verify shaft gears and differential bearing preloads.
Readjust bearing preloads if then are no within specification.

1. Set primary shaft gear assembly and differential into clutch hosing.

2. Install transaxle case, and tighten to specifed torque.

Tightening torque : 28~38 lb-ft (38~51 N·m, 3.8~5.3 kg-m)

3. Install SST(0K130 171 A05) to differential.

4. Connect torque wrench to SST(0I130 171 A05) and measure preload.

Preload : 13~17 lb-9n (1.4~1.9 N·m, 14~20 kg-cm)

5. Remove SST(0K130 171 A05).

6. With transaxle facing in direction shown in figure, install SST(0K130 171 A05) to primary shaft gear assembly.

7. Connect torque wrench to SST(0K130 171 A5) and measure preload.

Preload : 0.9~2.0 lb-in (0.1~0.2 N·m, 1.0~2.5 kg-cm)

8. Remove SST (0K130 171 A05), transaxle case, primary shaft gear assembly and differential.

9. Install secondary shaft gear assembly and transaxle case, and tighten to specified torque.