KIA RIO

Since 2000 of release

Repair and car operation



Kia Rio
+ 1.1. Short acquaintance to the car
+ 2. Engines A3E, А5D
+ 3. Greasing system
+ 4. Cooling system
+ 5. Fuel system
+ 6. Ignition system
+ 7. Coupling
- 8. A transmission
   - 8.1. A mechanical transmission
      8.1.1. Specifications
      8.1.2. Check of level of oil
      8.1.3. Oil replacement
      8.1.4. Replacement of an oil sealing ring
      8.1.5. Removal and transmission installation
      8.1.6. Dismantling, check and transmission assemblage
      8.1.7. Carter couplings and components картера transmissions
      8.1.8. A primary shaft of a transmission
      8.1.9. A secondary shaft of a transmission
      8.1.10. A choice of adjusting linings
      8.1.11. Differential
      8.1.12. The gear change mechanism
   + 8.2. Automatic transmission F4E–K
+ 9. Axes and power shafts
+ 10. A suspension bracket
+ 11. Wheels and tyres
+ 12. A steering
+ 13. Brake system
+ 14. A body
+ 15. Air central air
+ 16. The electric equipment







8.1.6. Dismantling, check and transmission assemblage
THE GENERAL DATA

Transmission elements

1 – a back cover;
2 – a counternut, 127–206 Nm;
3 – муфта the reverse gear synchronizer (A5D, A5E);
4 – конусная the reverse gear plug (A5D, A5E);
5 – a blocking ring of the synchronizer (A5D, A5E);
6 – the synchronizer of 5th transfer;
7 – a plug of 5th transfer;
8 – a gear wheel of 5th transfer;
9 – the plug of a gear wheel of 5th transfer;
10 – a secondary gear wheel of 5th transfer;
11 – a clamp stopper, 15–20 Nm, a spring and a steel ball;
12 – a bolt of fastening of a shaft of transfer of a backing, 18–25 Nm;
13 – картер transmissions;
14 – a shaft of transfer of a backing;
15 – an intermediate gear wheel of transfer of a backing;
16 – the management block;
17 – the lever of installation of a spring;
18 – a switching rod 1-oj/2nd transfers;
19 – a switching plug 1-oj/2nd transfers;
20 – a switching rod 5-oj/back transfers;
21 – the lever of a rod of switching 5-oj/back transfers;
22 – a switching rod 3-ej/4th transfers;
23 – the lever of a rod of switching 3-ej/4th transfers;
24 – a switching plug 3-ej/4th transfers;
25 – the block of gear wheels of a secondary shaft;
26 – the block of gear wheels of a primary shaft;
27 – differential;
28 – the switch of a lantern of a backing, 18,6–25,5 Nm;
29 – распорная the plug (A3E)

Dismantling

PERFORMANCE ORDER
1. Establish a transmission at stand OK130 990 007 with adapter OK130 175 011A.
2. Remove the bearing and a plug of deenergizing of coupling.
3. Remove щуп for measurement of level of oil.
4. Remove the gauge of speed.
5. Remove the switch of a lantern of a backing.
6. Remove a back cover.

The prevention

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

Do not use repeatedly unscrewed counternut.


7. Adaptation OK201 323 021 block a primary shaft of a transmission.
8. Simultaneously include gear wheels of 1st and 2nd transfers that the primary shaft of a transmission was not turned.
9. Unbend fillets of the plate fixing a counternut.

10. Turn away a counternut from a primary and secondary shaft and remove конусное a ring of a reverse gear and муфту the synchronizer from a primary shaft.


The prevention

Do not use the reused cylindrical pin.


11. Thin выколоткой and a hammer beat out a cylindrical pin of a plug of inclusion of 5th transfer.
12. Simultaneously in gathering remove a synchronizer ring, a plug of inclusion of 5th transfer, sliding муфту 5th transfer, a blocking ring and муфту gear wheels.
13. Remove a gear wheel of 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 картер transmissions.

The prevention

For removal картера transmissions 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 management block.
20. Remove the lever of installation of a spring.
21. Deduce from gearing of a gear wheel by 1st and 2nd transfers. Thin выколоткой and a hammer beat out a cylindrical pin of a plug of inclusion 1-oj/2nd transfers.

The prevention

Do not use the reused cylindrical pin.


22. Remove a rod and a plug 1-oj/2nd transfers.
23. Thin выколоткой and a hammer beat out a cylindrical pin of a plug 3-oj/4th transfers, remove a plug 3-oj/4th transfers and the lever of a rod of switching 3-ej/4th transfers.
24. Remove the E-shaped lock ring of fixing of a rod 5-oj/back transfers.
25. Thin выколоткой and a hammer beat out a cylindrical pin of a plug 5-oj/back transfers, remove a plug 5-oj/back transfers and the lever of a rod of switching 5-oj/back transfers.
26. Simultaneously remove primary and secondary shaft in gathering.

27. Remove differential.

Assemblage

PERFORMANCE ORDER

The prevention

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


1. Establish differential in картер transmissions.

The prevention

Be convinced that have not damaged an oil sealing ring at installation of a primary shaft.

Before installation grease a working edge of a sealing ring.

Grease the second external ring of the bearing in картере transmissions.


2. Establish in gathering primary and secondary shaft in картер transmissions.
3. Establish a plug 3-oj/4th transfers on sliding муфту 3-ej/4th transfers, then insert a rod 5-oj/back transfers to a plug and establish a pin of fastening of a rod 5-oj/back transfers.

The prevention

At installation use a new cylindrical pin.


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

The prevention

At installation use a new cylindrical pin.


6. Combine the lever of a rod of switching 3-ej/4th transfers with a rod and fix a cylindrical pin.
7. Combine a switching rod 3-ej/4th transfers with a switching plug 3-ej/4th transfers and fix a cylindrical pin.
8. Collect a switching plug 1-oj/2nd transfers with sliding муфтой 1-oj/2nd transfers and establish a rod 1-oj/2nd transfers.

The prevention

At installation use a new cylindrical pin.

At installation use a new E-shaped lock ring.


9. Combine a switching rod 1-oj/2nd transfers with a switching plug 1-oj/2nd transfers and fix a cylindrical pin.

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

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

The 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.

The inhaling moment: 7,8–11,3 Nm

16. Establish the block of management and fix bolts.

The inhaling moment: 7,8–11,3 Nm


The prevention

At installation of the block of management consider length of bolts (length of bolt A more B).


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

The prevention

Clear hermetic from interfaced surfaces картера couplings and transmissions.


19. Apply a thin film hermetic Threebond 1216T or 1216TB on interfaced surfaces картера couplings and transmissions.

20. Establish картер transmissions on картер couplings and fix bolts.

The inhaling moment: 18,6–25,5 Nm

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

The inhaling moment: 18,6–25,5 Nm


The 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-oj/back year it is more than 1-oj/2nd, 3-ej/than 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.

The inhaling moment: 15–20 Nm

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

The prevention

As the form of a ring of the synchronizer differs from each other at assemblage it it is necessary to consider.

In a ring of the synchronizer of transfer of a backing there are admissions of teeths in three places.


Pay attention to a direction of installation of the plug of a gear wheel of 5th transfer.

Length: A> B


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

The prevention

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


25. Establish a plug of 5th transfer to a flute of the synchronizer of 5th transfer.
26. Establish a synchronizer ring.
27. Establish on a primary shaft муфту the synchronizer and конусное a reverse gear ring.

The prevention

At installation use a new cylindrical pin.


28. Fix a plug of 5th transfer by a cylindrical pin.
29. Simultaneously include gear wheels of 1st and 2nd transfers that the primary shaft of a transmission was not turned.
30. Adaptation OK201 171 010 block a primary shaft of a transmission.

The prevention

At installation use a new counternut.


31. Tighten a counternut and for its fixing from отворачивания bend fillets of a plate fixing a counternut

The inhaling moment: 127–206 Nm

32. By the indicator of hour type measure люфт gear wheels of 5th transfer and конусной backing plugs.

Люфт:
Gear wheels of 5th transfer: 0,07–0,39 mm
The konusnoj plug of a backing: 0,1–0,25 mm


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


The prevention

Clear hermetic from interfaced surfaces of a back cover and картера transmissions.


33. Apply a thin film hermetic Threebond 1216T or 1216TB on interfaced surfaces картера a transmission and a back cover.

34. Establish a back cover taking into account position of deepening for конусной plugs of a backing and fix bolts.

The inhaling moment: 7,8–11,3 Nm

35. Establish a washer on the switch of a lantern of a backing and screw the switch.

The inhaling moment: 20–29,4 Nm

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

The inhaling moment: 7,8–11,3 Nm

37. Establish the plug on draught of a gear change.
38. Establish the bearing and a plug of deenergizing of coupling.
39. Remove a transmission from stand OK130 990 007 with adapter OK130175011A.

The prevention

Do not damage картер a transmission.


40. A screw-driver and a hammer beat out an external ring of the bearing of a secondary shaft with картера transmissions.