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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Sportage (1999 release)

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Kia Sportage
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Sportage
Introduction
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Engine
System of cooling, heating, ventilation and air conditioning
The power supply system, motor control / emission control and exhaust
Systems of an electric motor
A five-speed manual gearbox gear
Automatic Transmission
Transmission Line
general information
Clutch
Transfer case
Drive shafts
Bridges
Brakes
Suspension and steering
Body
Onboard electric
The control body dimensions
Wiring
 


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Transmission Line



Specifications

Separate characteristics are resulted also in the text of the chapter and in the case of compulsion of their performance are highlighted in bold.

Total information

The organizing principle of transmission line Manual transmission / EF (see. Specifications to the Head A five-speed manual gearbox shift and automatic transmission), all wheel drive (Part Time 4WD), - transfer case with 2-speed gearbox (splitter) and without a center differential, freewheel hub of the front wheel (vacuum or mechanical), two drive shafts, continuous rear axle.

Coupling (models with Manual transmission)

Type Dry, single plate
Drive clutch Hydraulic with a common path with the brake reservoir
The type and amount of hydraulic fluid See. Specifications to the Head Current leaving and service
Grease release bearing (see. Mori White TA No.2
Flywheel
  • Maximum permissible value of cross-beats (see. mm
0.2
  • Maximum allowable depth of bore mm
0.5
Basket
  • Type
With the diaphragm spring
  • Operating force the pressure plate, kgf
530
Slave drive
  • Outside diameter, mm
225
  • Inner diameter, mm
150
  • The thickness of the friction linings, mm
    • Nominal value
3.5
    • The limit value
0.3
    • Maximum permissible value of cross-beats (see. mm
0.7
    • Maximum permissible value of the radial runout mm
10
Clutch pedal (see.
  • Type
Hanging
  • Shoulder
6.9: 1
  • Full speed, mm
155
  • Free lift, mm
    • Setpoint
12.7
    • The allowable range
8 ÷ 18
  • Height (in view panel carpeting), mm
250
  • Off height, mm
184
Master Cylinder
  • Bore, mm
15.9
Executive cylinder
  • Bore, mm
19.1

Transfer case

Type With the two-stage gear (splitter)
Drivetrain front output shaft Chain drive
The type and amount of the lubricating fluid See. Specifications to the Head Current leaving and service
The gear ratio shift stage High / Low 1.000 / 1.981

Drive shafts

The geometrical parameters (see. Graphic design driveshafts)
  • The length (L), mm
    • The front shaft
700
    • Rear shaft
      • Models 5-door station wagon
1061
      • Convertible models
775
Outside diameter, mm
  • The front shaft
50.8
  • Rear shaft
63.5
Maximum allowable amount of bending of the shaft (see. mm 0.4
The list produced retaining rings universal joints
  • Detail number
Thickness

1757 25 171

1.22

1757 25 172

1.24

1757 25 173

1.26

1757 25 174

1.28

1757 25 175

1.30

1757 25 176

1.32

1757 25 177

1.34

1757 25 178

1.36

1757 25 179

1.38

Bridges

Type
  • Front axle
Cutting, equipped with hypoid final drive with differential unblockable, equipped with two constant velocity joints (CV joints) drive shafts and automatic Hub freewheel with a vacuum or a mechanical drive
  • Rear Axle
Rigid (hard), equipped with a hypoid final drive with unlockable (standard) or self-locking LSD-type (optional) differential and two semi-axes

Front axle

The type and amount of the lubricating fluid See. Specifications to the Head Current leaving and service
Preload wheel bearings, Nm 0.88 ÷ 1.14
Maximum permissible amount of movement of wheel bearings (see. mm 0.1
The gearbox final drive
  • Type
Hypoid type helical gear direct engagement
  • Designation
    • Petrol models
      • Models with Manual transmission
        • With ABS
K08C
        • Without ABS
K04W
      • Models AT
        • With ABS
K08A
        • Without ABS
K04L
  • Diesel models (Manual / AT)
    • With ABS
K04F
    • Without ABS
K08I
The number of gear teeth
  • Pinion (all models)
9
  • Driven gear
    • Petrol models
      • Models with Manual transmission
37
      • Models AT
43
    • Diesel models (Manual / AT)
40
  • Gear ratio
    • Petrol models
      • With Manual transmission
4.625: 1
      • With AT
4.778: 1
    • Diesel models (Manual / AT)
4.444: 1
The length of the sleeve remote differential mm 54.80 ÷ 56.09

Maximum permissible differential backlash gearing - is regulated by the selection of thrust washers, mm
0 ÷ 01
Identification Marking the thickness of thrust washers and side gears

Marking

Thickness

0

2.00

5

2.05

1

2.10

15

2.15

2

2.20

Depth caulking fixing pin axis of satellites, mm
1

Fixing ring gear, the scheme and the amount of sealant application, see 3
0.04
Preload drive pinion, - regulated by the selection of thrust washers, Nm
  • Stage 1 (without installing the gland)
0.9 ÷ 1.4
  • Stage 2 (after the installation of the gland)
1.6 ÷ 2.1

Identification Marking the thickness of thrust washers and the drive pinion

Marking

Thickness

8

3.08

eleven

3.11

14

3.14

17

3.17

20

3.20

23

3.23

26

3.26

29

3.29

32

3.32

35

3.35

38

3.38

41

3.41

44

3.55

47

3.47

The magnitude of the lateral runout of the connecting flange, mm
less than 0.06

The amount of backlash gearing main gear, mm

0.12 ÷ 0.14

Checking the quality of the contact engagement
main gear using
red lead

The distance between the guide section covers bearings, mm
185.425 ÷ 185.500
Drive shafts
  • Type hinges
    • From the differential
Hinges double compensation
    • From the wheels
Ball constant velocity joints (CV joints)
  • Length mm
    • Left shaft
596.2
    • Right shaft
528.7
  • Diameter, mm
27.1

Rear Axle

The type and amount of the lubricating fluid See. Specifications to the Head Current leaving and service
The gearbox final drive See. The specifications for the front axle
Semiaxes
  • Length mm
    • The left axle shaft
716.5
    • The right half
762.5
  • Maximum allowable amount of bending (see. mm
10

Efforts of a tightening of carving connections, Nanometer

Efforts of a tightening of certain fastener elements can be shown directly in the section where they are highlighted in bold.

Clutch

A locknut clutch pedal all the way (see. 14. ÷ 18
The nut of the master cylinder pushrod 12 ÷ 17
Nut bolt axial clutch pedal 20 ÷ 34
Nuts of fastening of the main cylinder 19 ÷ 26
Flare nuts hydraulic lines to the master cylinder 16 ÷ 23
Bolts slave cylinder on the crankcase RKPP 19 ÷ 26
Flare nuts hydraulic lines to the actuator cylinder and a flexible hose 13 ÷ 22
Pumping valve actuator cylinder 5.8 ÷ 7.5
Flywheel bolts (8 pcs) 96 ÷ 103
Bolts clutch 18 ÷ 26

Transfer case

The gauge-switch activate 4WD 20
Filler / inspection hole thirty
Drain plug thirty
Bolts lateral support (2 pcs) 23
Nuts of fastening of lateral support (2 pcs) 40
Bolts of fastening of the lever of switching of modes to dropbox thirty
Bolts / nuts clamping flange anther gear shift modes 20
Bolt clutch speedometer 7

Nuts of fastening flanges output shafts (see. Section Replacement seals output shafts) 111
Bolts transfer case to the crankcase Manual transmission / AT 44
Bolts central support to the cross beam thirty
Bolts crossbeam to the frame (8 pieces) 44
Bolts main bearing cover plate (TORX, 5 pcs) 16
Bolts of a cover of a chain drive 44
Plugs switching rod in the crankcase of the box 44
Bolts that secure the front cover to the transaxle case 28
Bolts that secure the front cover to the bearing cover 7

Drive shafts

Bolts / nuts driveshafts to the connecting flanges of the leading main gear axles 34.3 ÷ 37.3
Bolts / nuts driveshafts to the connecting flange output shafts of the transfer case 49 ÷ 59

Bridges

Front axle

Drain plug gear case 39 ÷ 54
Filler / stopper control gear case thirty
Bolts Kit
  • Step 1
25
  • Step 2
31
Hub nut 118 ÷ 157
Bolts brake board 16 ÷ 23
Hub bolts 147
Bolts of fastening the bearing housing to the sleeve housing bridge 36 ÷ 54
Bolts driven gear to the differential housing 69 ÷ 83
Bolts of fastening of covers of bearings bearing box in the gear differential
37 ÷ 52
Bolts differential assembly to the axle housing
  • M8
23 ÷ 26
  • M10
36 ÷ 34
Nut connecting flange drive pinion 128 ÷ 284
Bolts locking plate 18 ÷ 26

Rear Axle

Drain plug gear case 39 ÷ 54
Filler / stopper control gear case thirty
Bolts of fastening of the stuffing box half-axis to the sleeve housing bridge 88 ÷ 108
Nut connecting flange drive pinion 128 ÷ 284
Bolts driven gear to the differential housing 69 ÷ 83

Bolts front axle assembly
  • A
49 ÷ 80
  • AT
69 ÷ 103

Bolts of fastening of covers of bearings supporting the differential housing in the gear unit (see. The data on the front axle) 37 ÷ 52
Bolts locking plate 18 ÷ 26
ABS sensor mounting bolt to the gear unit 7.8 ÷ 11.7
Bolts differential assembly to the axle housing
M8 23 ÷ 26
M10 49 ÷ 54




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