KIA RIO

Since 2000 of release

Repair and car operation

8.1.9. A secondary shaft of a transmission

THE GENERAL DATA

Secondary shaft of a transmission

1 – a double cone; 2 – an internal ring of the synchronizer; 3 – the gear wheel plug 2nd transfers; 4 – the needle bearing; 5 – a gear wheel 2nd transfers; 6 – a gear wheel of 3 transfers; 7 – распорная the plug; 8 – a gear wheel of 4th transfer; 9 – an internal ring of the bearing; 10 – an internal ring of the bearing;

11 – a secondary shaft; 12 – a gear wheel of 1st transfer; 13 – a synchronizer ring; 14 – a backing gear wheel; 15 – a clamp cracker; 16 – a nave муфты the synchronizer; 17 – a synchronizer spring; 18 – a synchronizer ring; 19 – the synchronizer 1-oj/2nd transfers

Preliminary check

BACKLASH OF THE GEAR WHEEL OF 1 TH TRANSFER

PERFORMANCE ORDER

1. Measure a backlash between a gear wheel of 1st transfer and a differential gear wheel. Nominal backlash: 0,05–0,28 mm 2. If the backlash exceeds admissible value, check up a surface of contact of a gear wheel of 1st transfer, a gear wheel of differential and муфты the synchronizer 1-oj/2nd transfers. Replace the worn out or damaged details.

BACKLASH OF THE GEAR WHEEL OF 2 TH TRANSFER

PERFORMANCE ORDER

1. Measure a backlash between a gear wheel 2nd transfers and a gear wheel of 3 transfers. Nominal backlash: 0,05–0,17 mm 2. If the backlash exceeds admissible value, check up a surface of contact of a gear wheel 2nd transfers, gear wheels of 3 transfers and муфты the synchronizer 1-oj/2nd transfers. Replace the worn out or damaged details.

Dismantling

THE BEARING AND GEAR WHEEL OF 4 TH TRANSFER

PERFORMANCE ORDER

Using a press and special adaptation OK201 172 008 remove a gear wheel of 4th transfer.

GEAR WHEELS OF 2 TH AND 3 TRANSFERS

PERFORMANCE ORDER

1. Move gear wheels to shesterne1 th transfer. 2. Using a press and special adaptation OK201 172 008 remove a gear wheel 2nd and a gear wheel of 3 transfers.

Check

GEAR WHEELS

PERFORMANCE ORDER

1. Examine synchronizer cones on absence of deterioration. 2. Examine a condition of a surface of teeths of gear wheels on absence of damages, deterioration and cracks. 3. Visually check up a condition of a ring of the synchronizer on absence of damages, deterioration and cracks.

SYNCHRONIZER RING

PERFORMANCE ORDER

1. Visually check up a condition of teeths of a ring of the synchronizer on absence of damages, deterioration and cracks. 2. Check up a condition of a conic surface on absence of damages, deterioration and cracks. 3. Establish a synchronizer ring in a gear wheel. 4. Measure a backlash between a ring of the synchronizer and a surface of a flange of a gear wheel. Nominal backlash: 1,4–1,7 mm Is minimum admissible backlash: 0,8 mm

THE SYNCHRONIZER

PERFORMANCE ORDER

1. Visually check up a condition of the synchronizer and its working capacity. 2. Visually check up a condition of teeths of a ring of the synchronizer on absence of damages, deterioration and cracks. 3. Check up a condition of crackers of a clamp on absence of damages, deterioration and cracks. 4. Measure a backlash between sliding муфтами the synchronizer and plugs. Backlash, mm Element The nominal Maximum permissible 1-aja/2nd 0,1–0,35 0,75 3-ja/4th 0,27–0,50 1,80

INTERMEDIATE GEAR WHEEL OF THE BACKING

PERFORMANCE ORDER

1. Visually check up a condition of teeths of a gear wheel on absence of damages, deterioration and cracks. 2. Measure a backlash between the plug of an intermediate gear wheel of a backing and the lever. Nominal backlash: 0,095–0,33 mm Is minimum admissible backlash: 0,31 mm

THE BEARING

PERFORMANCE ORDER

Check up the bearing on absence of damages and smoothness of rotation.

PRIMARY AND SECONDARY SHAFT

PERFORMANCE ORDER

1. Check up surfaces of gear wheels contacting to shaft on absence of deterioration and damages. 2. Check up шлицы shaft on absence of deterioration and damages. 3. Visually check up a condition of teeths of gear wheels on absence of damages, deterioration and cracks. 4. Check up a condition of the channel for greasing giving on absence of a contamination. 5. By the indicator of hour type measure palpation of primary and secondary shaft. Palpation: 0,015 mm The prevention If replacement of a secondary shaft was spent, adjust a preliminary tightness of the bearing. Oil a backlash, mm Element Shaft (external diameter) Gear wheel (internal diameter) Backlash 1st 39,445–39,470 39,500–39,525 0,03–0,08 2nd 35,145–35,170 47,009–47,025

Assemblage

NAVE МУФТЫ OF THE SYNCHRONIZER

PERFORMANCE ORDER

Establish crackers of a clamp and a spring in a nave муфты the synchronizer. The sizes of a cracker of a clamp, mm Element 1 2 3 1-aja/2nd 18,0 4,25 5,0 3-ja/4th 17,0 4,25 5,0 4-aja/З.х. 17,0 4,25 5,0

THE BEARING (FROM OUTSIDE DIFFERENTIAL)

PERFORMANCE ORDER

Using a press and special adaptation OK900 175 AA1 establish the new bearing.

GEAR WHEEL OF 1 TH TRANSFER, RING OF THE SYNCHRONIZER OF 1 TH TRANSFER AND THE SYNCHRONIZER 1-OJ/2 TH TRANSFER

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The prevention

On a synchronizer ring 2nd transfers are absent teeths in three places on perimetre to distinguish it from other rings of the synchronizer.

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PERFORMANCE ORDER

1. Establish a gear wheel of 1st transfer, a ring of the synchronizer of 1st transfer and the synchronizer 1-oj/2nd transfers how it is shown in drawing. 2. Combine dredging of a ring of the synchronizer with clamp crackers. 3. Using a press and special adaptation OK900 175 AA1 establish a nave муфты the synchronizer 1-oj/2nd transfers.

RING OF THE SYNCHRONIZER OF 2 TH TRANSFER AND GEAR WHEEL OF 2 TH AND 3 TRANSFERS

PERFORMANCE ORDER

1. Establish a synchronizer ring 2nd transfers and a gear wheel 2nd transfers. 2. Using a press and special adaptation OK900 175 AA1 establish a gear wheel of 3 transfers.

GEAR WHEEL OF 4 TH TRANSFER AND INTERNAL RING OF THE BEARING

PERFORMANCE ORDER

1. Using a press and special adaptation OK900 175 AA1, establish a gear wheel of 4th transfer and an internal ring of the bearing. 2. Measure a backlash between a gear wheel of 1st transfer and a gear wheel of a drive of differential. Nominal backlash: 0,05–0,28 mm 3. Measure a backlash between a gear wheel 2nd and 3 transfers. Nominal backlash: 0,10–0,22 mm 4. If backlashes do not correspond demanded, disassemble and repeatedly collect a secondary shaft.