REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Clarus (1995 issue)

general info. full specifications. diagnostics. hints. tips. tricks

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Kia
	Clarus
		Maintenance
		Engines FE DOHC and DOHC T8
		Greasing system
		Cooling
		The power supply system and release
		Fuel system
		Ignition system
		Coupling
		Manual transmission
			Technical data
			Checking the oil level
			Change of oil
			Removing gearbox
			Installing gearbox
			The general recommendations about transmission dismantling
			Dismantling, check of the fifth / reverse gear and crankcase
			Dismantling of knots clutch and the gearbox
			Replacing the oil seal of the differential car
			Dismantling of a primary shaft of a transmission
			Dismantling of a secondary shaft of a transmission
			Checking the details of primary and secondary shaft
			General recommendations for assembly
			Assemblage of a secondary shaft
			Assembling input shaft
			Assemblage, check of the fifth / reverse gear and crankcase
			Selecting shims
			Differential bearing preload
			Adjustable bearing preload
			Remarks on transmission assemblage
			Differential
			The gear change mechanism
			Troubleshooting
		ACP G4A-EL
		AKP 50-40 LE
		Axes and power shafts
		Steering
		Wheels and tires
		Suspension
		Body
		The air conditioning system
		Electrical equipment
		Brakes
		Electric schemes

Remarks on transmission assemblage

Differential oil seal

PERFORMANCE ORDER

1. Using the special adaptation OK201 170 AA1 and a hammer easy blows evenly hammer new oil seal is a special tool comes into contact with the transmission case.
	2. Coat the lip of the oil seal with gear oil.

Differential Bearing Ring

PERFORMANCE ORDER

1. Install the shim to the differential case.
	2. Grease the bearing ring gear oil and using pipes set it to differential case.

Diaphragm spring

PERFORMANCE ORDER


	Install the diaphragm spring, as shown in the figure.

Ring bearing transmission case

PERFORMANCE ORDER

1. Install the shims in the nests of bearings of primary and secondary shaft in the gearbox.
	2. Lubricate each ring of the bearing with gear oil and install them in the transmission housing by a pipe.

Oil seal traction shift control assembly

PERFORMANCE ORDER

1. Using the pipe, install a new oil seal.
	2. Coat the lip of the oil seal with gear oil. The outer diameter of the pipe: 26.0 mm

Case

PERFORMANCE ORDER


	Install cover so that when installed in the automobile discharge outlet is downwards.

Oil seal input shaft

PERFORMANCE ORDER


	Lubricate the outer surface of the oil seal with gear oil and using the tube set it to the gearbox housing.

Bearing preload

Check preload bearing shafts and differential. Readjust preload bearing, if it does not meet the required values.

PERFORMANCE ORDER

1. Install the input shaft assembly and the differential in the clutch housing.
	2. Place the gearbox housing and tighten to the required torque. Torque: 38-51 N ??? m
3. Replace the differential special adaptation OK130 171 A05.
	4. Replace the special adaptation OK130 171 A05 torque wrench and measure the preload. Preload: 1.4-1.9 N ??? m
5. Remove special adaptation OK130 171 A05.
6. Turn the transmission in the direction shown in the figure, set the special adaptation OK130 171 aa0 on the input shaft assembly.
	7. Replace the special adaptation OK130 171 aa0 torque wrench and measure the preload. Preload: 0.1-0.2 N ??? m
8. Remove special adaptation OK130 171 aa0, gearbox housing, input shaft assembly and a differential.
	9. Install the output shaft assembly and the transmission case and tighten to the required torque. Torque: 38-51 N ??? m
10. Establish special adaptation OK130 171 aa0 the secondary shaft assembly.
11. Establish on special adaptation OK130 171 aa0 torque wrench and measure the preload. Preload: 0.2-0.4 N ??? m

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Differential