Kia Carens. Manual — part 183

2001 > 1.8L DOHC >

Disassembly

Secondary shaft assembly

1. Measure thrust clearance of 1st gear and 2nd gear before disassembly, refer to Preinspection.

2. Disassemble in order shown in figure, refer to Disassembly note.

Preinspection

Secondary 1st gear thrust clearance

1. Measure clearance between secondary 1st ear and differential drive gear.

Clearance : 0.002~0.011 in (0.05~0.28 mm)
Maximum : 0.013 in (0.33mm)

2. If clearance exceeds maximum, check contact surfaces of secondary 1st, gear, differential drive gear of

secondary shaft, and 1 st/2nd clutch hub assembly.
Replace worn and damaged parts.

Secondary 2nd gear thrust clearnace

1. Measure clearance between secondary 2nd gear and secondary 3rd gear.

Clearance : 0.007~0.018 in (0.18~0.46 mm)
Maximum : 0.020 in (0.54 mm)

2. If clearance exceeds maximum, check contact surfaces of secondary 2nd gear, secondary 3rd gear, and

1st/2nd clutch hub assembly. Replace worn and damaged parts.

Bearing and secondary 4th gear

1. Remove bearing and secondary 4th gear by using SST(0K201 172 008).

Secondary 3rd gear and Secondary 2nd gear

1. Remove retaining ring.

2. Shift gears to 1st gear.

3. Remove secondary 3rd gear and secondary 2nd gear by using SST(0K201 172 008)

1st/2nd clutch nub assembly, 1st synchronizer ring, and secondary 1st gear

1. Remove retaining ring.

2. Remove 1st/2nd clutch hub adsembly. 1st gear synchronizer ring, and secondary 1st gear using press.

Bearing (differential drive gear end)

1. Remove bearing by using SSTs.

Disassembly

Clutch hub assembly

1. Inspect clutch hub sleeve and bun operation.

2. Inspect gear teeth for damage, wear, and cracks.

3. Inspect synchronizer keys for damage, wear and cracks.

4. Measure clearance between clutch nub sleeves and shift forks.

Clearnace

Standard (in (mm))

Maximum (in(mm))

1st/2nd

0.004~0.018 (1.01~0.45)

0.037(0.95)

3rd/4th

0.004~0.016(0.10~0.40)

0.035(0.90)

5th/Rev.

0.004~0.014(0.10~0.36)

0.034(0.86)

Reverse idle gear and reverse lever

1. Inspect gear teeth for damage, wear and cracks.

2. Measure clearance between reverse idle gear bushing and revese lever.

Standard clearance : 0.011~0.013 in (0.28~0.3 mm)
Maximum : 0.020 9n (0.5 mm)

Bearing

1. Inspect for damage and rough rotation.

Primary shaft and ssecondary shaft

1. Inspect gear contact surface for damage and wear.

2. Inspect splines for damage and wear.

3. Inspect gear teeth for damage, wear and cracks.

4. Inspect oil passenger for clogging.

5. Measure primary and secondary shaft runout.

Primary shaft runout : 0.002 in (0.05 mm) max.

Secondary shaft runout : 0.0006 in (0.015 mm) max.

If shaft is replaced, adjust bearing preload.

6. Determine Clearance between shafts and gears.

Clearance (in (mm))

Shaft

(Outer dia.)

Gear

(Linner dia.)

Sleeve

(Outer dia.)

Clearance

1st

1.553~1.554

(39.445~39.470)

1.555~1.556

(39.500~39.525)

-

0.001~0.003

(0.03~0.08)

2nd

1.376~1.377

(34.945~39.970)

1.378~1.379

(35.000~35.025)

-

3rd

1.415~1.416

(30.945~30.970)

1.417~1.418

(36.000~36.025)

-

4th

1.218~1.219

(30.945~30.970)

1.221~1.222

(31.000~31.025)

-

5th

-

1.339~1.40034.

(34.000~34.025)

1.336~1.337

(33.945~33.970)