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

printable version

Removing gearbox

Removal steps manual gearbox

1 - the storage battery;
2 - support the battery;
3 - housing;
4 - fresh air intake;
5 - the air filter assembly;
6 - connector reversing light switch;
7 - wire connection with "weight";
8 - speed sensor connector;
9 - a wheel and tire;
10 - mudguard;
11 - cross;
12 - draft of a gear change;
13 - Rod shift control;

14 - a tip of steering draft;
15 - earring fastening of the stabilizer;
16 - drive shaft;
17 - an intermediate shaft;
18 - Corner Panel;
19 - Front collector;
20 - starter;
21 - mounting bracket of the engine;
22 - the working cylinder of coupling;
23 - support number 2 engine;
24 - Bearing number 1 engine;
25 - support number 4 engine;
26 - Transmission.

Withdrawal

PERFORMANCE ORDER

1. Remove the first wire from the negative battery terminal, then from positive. Remove the battery support.
2. Raise the vehicle and drain the transmission fluid into a suitable container.
3. Remove the top casing of the engine.
4. Remove the bolt and remove the intake of fresh air.
5. Remove the air filter assembly.
6. Disconnect the reverse gear switch.
7. Remove the bolt and disconnect a wire of connection with "weight".
8. Disconnect the vehicle speed sensor.
9. Loosen the screws on both front wheels.
10. Lift the car and fix on support.
11. Remove both front wheels.
12. Remove the two screws and remove the mudguard.
13. Remove the nut and disconnect from a transmission draft of a gear.
14. Remove the nut and bolt, remove the clamp and disconnect the traction shift control of the transmission.
15. Remove the bolts and nuts and remove the crossmember.
16. Remove the cotter pin locking nuts tie rod.
A warning Sharp edges can cut a stripper dust cover tie rod. Install the puller so that the sharp edges were between a dustproof cover and swivel.
	17. Unscrew the nut to make it flush with the end of the ball stud. With the help of a stripper squeeze out the tie rod end from the steering knuckle.
18. Turn out nuts and disconnect the left and right tips of steering drafts from rotary fists.
19. Remove the nut on each side and remove the earrings stabilizer bar.
	20. Turn out a coupling bolt ball joint of the lower arm. Wrap a cloth dust seal ball joint.
	21. mount wring out the bottom lever downwards and separate a pin joint from the steering knuckle on both sides of the car.
A warning Sharp edges of the locking ring of the drive shaft can be cut or damage the oil seal. Be careful when removing the drive shaft.
	22. Insert mount between an internal SHRUS drive shaft and a transmission and easy blow on mount take a power shaft from a transmission. To eliminate free sagging soft wire tie up a power shaft to a body.
23. Remove the bolts and remove the support of the drive shaft to the engine block.
24. Remove the screws and remove the base manifold.
25. Remove the starter mounting bolts and remove it.
	26. Remove the bolts clutch slave cylinder.
27. Move the clutch slave cylinder and conduit to a place where they will not interfere with transmission removal.
	28. Before removing the engine mounting bracket using the tool OK201 170 aa0 support the engine.
29. Remove the engine mount bracket,
30. Remove the engine support and tilt the engine to the transmission.
31. Support a transmission jack.
	32. Turn out bolts of fastening of a transmission.
33. Carefully separate the transmission from the engine and slowly lower it under the car.

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Installing gearbox