Kia Carens. Manual - part 184

Vehicle speed sensor (speedometer driven gear)

1. Inspect teeth for damage and wear.

2. Inspect O-ring for damage and wear.

Inspection

Inspect all parts and repair or replsce as necessary.

Gears

1. Inspect synchronzer cones for wear.

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

3. Inspect synchronizer ring matching teeth for damage and wear.

Synchronizer ring

1. Inspect synchronizer ring teeth for damage. wear and cracks.

2. Inspect tapered surface for wear and cracks.

3. Set synchronizer ring squarely in gear.

4. Measure clearance between synchronizer ring and flank surface of gear.

Standard clearance : 0.059 in (1.5 mm)
Minimum : 0.031 in (0.8 mm)

Secondary shaft assembly

Assembly Precaution

1. Replace all O-rings and gaskets.

2. Verify that all parts are completely clean before assembly.

3. Assemble parts within 10 minutes after applying sealant. Allow allsealant to cure for at least 30 minutes

after assembly vefore filing transaxle with oil.

4. Replace bearing races and bearings as sets.

Assemble in order shown in figure, refer to Assembly note.

Clutch hub Assembly note

1st/2nd

0.748 (19.0)

0.167(4.25)

0.197(5.0)

3rd/4th

5th/Rev.

0.669(17.0)

0.167(4.25)

0.197(5.0)

1. Install synchronizer keys and springs in clutch hub.

Bearing (differential drive gear end)

1. Install new bearing by using SST(0K130 175 A11).

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

The 1st synchronizer ring has teeth missing at three places around its outer edge to help distinguish it
from other synchronizer rings.

1. Assemble secondary 1st gear, 1st synchronizer ring, and 1st/2nd clutch nub assembly as shown in figure.

2. Align synchronizer ring grooves and synchronizer keys.

3. Press on 1st/2nd clutch nub assembly by using SST(0K990 175 A11)

2nd synchronizer ring, 2nd gear and secondary 3rd gear

1. Install 2nd synchronizer ring and secondary 2nd gear.

2. Install secondary 3rd gear by using SST(0K130 175 A13/0K011 270 A02/0K130 175 A11).

Secondary 4th gear and bearing

1. Install secondary 74th gear and bearing by using SST(0K130 175 A13/0K011 270 A02/0K130 175 A11).

2. Measure clearance between 1st gear and differential drive gear.

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

3. Measure clearance betweeen secondary 2nd gear and secondary 3rd gear.

Clearance : 0.007~0.018 in (0.18~0.46 mm)
Maximum : 0.020 in (0.51 mm)

4. If not as specified, disassemble and reassemble secondary shaft assembly.