Kia Carens. Manual - part 121

Secondary 5th gear

1. Install secondary 5th gear as shown.

5th/reverse clutch nub assembly and 5th/reverse shift fork

1. Install 5th/reverse clutch nub assembly and 5th/reverse shift fork together.

Locknut

1. Shift to 1st gear.

2. Lock primary shaft using SST(0K201 323 021).

3. Tightening new locknuts onto primary and secondary shafts.

Tightening torque : 94~145 lb-ft (128~196 N·m, 13~20 kg-m)

4. Stake locknuts.

5. Measure the 5th gear thrust clearance using a dial indicator.

Clearance : 0.004~0.009 in (0.10~0.22 mm)
Maximum : 0.011 in (0.27 mm)

6. If not as specified, disassemble and reassemble 5th and reverse gear assemblies.

Bearing preload adjustment

When replacing any of parts listed in table below, adjust bearing preload by selection and installing proper adjustment
shim(s).

Primary shaft assembly

Secondary shaft assembly

Differential

· Transaxle case
· Clutch housing
· Primary shaft gear bearing
· Primary shaft gear

· Transaxle case
· Clutch housing
· Secondary shaft gear bearing
· Secondary shaft gear
· Secondary 4th gear

· Transaxle case
· Clutch housing
· Differential side bearing
· Ring gear and gear case assembly

SST usage

1. Install primary and secondary shaft bearing races into transaxle case (diaphragm springs and shims removed)

2. Mount clutch housing onto transaxle hanger, and set differential bearing race into clutch housing.

Position piece of pipe against bearing race and tap it in until it contacts clutch housing.

3. Set bearing races into SST(0K900 175 A01/0K900 175 A02/0K900 175 A03) as shown in figure.

4. Turn selector to eliminate gap indicated by arrow.

5. Set differential assembly into clutch housing, and set bearing race and SST(0K900 175 A03) on differential. Set

assembled selectors for primary and secondary shaft in clutch housing.
Mount shaft gear assemblies as shown in figure.

6. Set SST(0K130 175 A02) in positions shown in figure.

7. Install transaxle case and tighten SST(0K130 191 A07) to specified torque.

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

8. To seat bearings, mount SST(0K130 175 A03) on parts   and   of selectors, and turn selectors so gaps are widened.

Then turn SST(0K130 175 A03) in reverse direction until gaps are eliminated.

9. Manually expand selector until it no longer turns by hand.

10. Verify that both primary and secondary shafts turn smoothly.

11. Measure clearance between two halves of SST(0K900 175 A01) around circumference by using feeler gauge.

12. Take maximum reading and determine shim to be used. Use no more than twon shims.

Primary shaft adjustment shim

• Subtract diaphragm spring thickness (0.026 in {0.65 mm}) from gap determined in STE 11 for primary shaft.
• Make shim selection range by subtracting standard clearance parameters from result in previous step.
• Select thinner shim within range to obtain standard clearance.