Rio KIA
+ 1.1. Short acquaintance to the car
+ 2. Engines A3E, A5D
+ 3. Greasing system
+ 4. Cooling system
+ 5. Fuel system
+ 6. Ignition system
+ 7. Coupling
- 8. Transmission
- 8.1. Mechanical transmission
8.1.1. Specifications
8.1.2. Check of level of oil
8.1.3. Oil replacement
8.1.4. Replacement of an oil sealing ring
8.1.5. Removal and transmission installation
8.1.6. Dismantling, check and transmission assembly
8.1.7. Case of coupling and components of a case of a transmission
8.1.8. Primary shaft of a transmission
8.1.9. Secondary shaft of a transmission
8.1.10. Choice of adjusting laying
8.1.11. Differential
8.1.12. Gear shifting mechanism
+ 8.2. Automatic transmission of F4E-K
+ 9. Axes and power shafts
+ 10. Suspension bracket
+ 11. Wheels and tires
+ 12. Steering
+ 13. Brake system
+ 14. Body
+ 15. Air central air
+ 16. Electric equipment
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Secondary shaft of a transmission
1–double cone;
2–internal ring of the synchronizer;
3–plug of a gear wheel of the 2nd transfer;
4–needle bearing;
5–gear wheel of the 2nd transfer;
6–gear wheel of the 3rd transfer;
7–rasporny plug;
8–gear wheel of the 4th transfer;
9–internal ring of the bearing;
10-internal ring of the bearing; |
11-secondary shaft;
12-gear wheel of the 1st transfer;
13-synchronizer ring;
14-backing gear wheel;
15-clamp cracker;
16-nave of the coupling of the synchronizer;
17-synchronizer spring;
18-synchronizer ring;
19-synchronizer 1-ой/2nd of transfers |
Preliminary check
GAP OF THE GEAR WHEEL OF THE 1ST TRANSFER
| PERFORMANCE ORDER |
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1. Measure a gap between a gear wheel of the 1st transfer and a differential gear wheel.
Nominal gap: 0,05–0,28 mm |
| 2. If the gap exceeds admissible value, check a surface of contact of a gear wheel of the 1st transfer, a gear wheel of differential and the coupling of the synchronizer 1-ой/of the 2nd of transfers. Replace the worn-out or damaged details. |
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GAP OF THE GEAR WHEEL OF THE 2ND TRANSFER
| PERFORMANCE ORDER |
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1. Measure a gap between a gear wheel of the 2nd transfer and a gear wheel of the 3rd transfer. Nominal gap: 0,05–0,17 mm
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| 2. If the gap exceeds admissible value, check a surface of contact of a gear wheel of the 2nd transfer, a gear wheel of the 3rd transfer and the coupling of the synchronizer 1-ой/of the 2nd of transfers. Replace the worn-out or damaged details. |
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Dismantling
BEARING AND GEAR WHEEL OF THE 4TH TRANSFER
| PERFORMANCE ORDER |
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Using a press and the special adaptation OK201 172 008 remove a gear wheel of the 4th transfer. |
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GEAR WHEELS OF THE 2ND AND 3RD TRANSFERS
| PERFORMANCE ORDER |
| 1. Move gear wheels to the шестерне1st transfer. |
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2. Using a press and the special adaptation OK201 172 008 remove a gear wheel of the 2nd and a gear wheel of the 3rd transfer. |
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Check
GEAR WHEELS
| PERFORMANCE ORDER |
| 1. Examine synchronizer cones on lack of wear. |
| 2. Examine a condition of a surface of teeths of gear wheels on absence of damages, wear and cracks. |
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3. Visually check a condition of a ring of the synchronizer on absence of damages, wear and cracks. |
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SYNCHRONIZER RING
| PERFORMANCE ORDER |
| 1. Visually check a condition of teeths of a ring of the synchronizer on absence of damages, wear and cracks. |
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2. Check a condition of a conic surface on absence of damages, wear and cracks. |
| 3. Establish a synchronizer ring in a gear wheel. |
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4. Measure a gap between a ring of the synchronizer and a surface of a flange of a gear wheel. Nominal gap: 1,4–1,7 mm
Minimum admissible gap: 0,8 mm
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SYNCHRONIZER
| PERFORMANCE ORDER |
| 1. Visually check a condition of the synchronizer and its working capacity. |
| 2. Visually check a condition of teeths of a ring of the synchronizer on absence of damages, wear and cracks. |
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3. Check a condition of crackers of a clamp on absence of damages, wear and cracks. |
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4. Measure a gap between sliding couplings of the synchronizer and forks. |
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Gap, mm
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Element
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The nominal
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Maximum permissible
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1-ая/the 2nd
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0,1–0,35
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0,75
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3-ья/the 4th
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0,27–0,50
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1,80
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INTERMEDIATE GEAR WHEEL OF THE BACKING
| PERFORMANCE ORDER |
| 1. Visually check a condition of teeths of a gear wheel on absence of damages, wear and cracks. |
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2. Measure a gap between the plug of an intermediate gear wheel of a backing and the lever. Nominal gap: 0,095–0,33 mm
Minimum admissible gap: 0,31 mm
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BEARING
| PERFORMANCE ORDER |
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Check the bearing on absence of damages and smoothness of rotation. |
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PRIMARY AND SECONDARY SHAFT
| PERFORMANCE ORDER |
| 1. Check surfaces of gear wheels contacting to shaft on lack of wear and damages. |
| 2. Check shlitsa of shaft on lack of wear and damages. |
| 3. Visually check a condition of teeths of gear wheels on absence of damages, wear and cracks. |
| 4. Check a channel condition for supply of greasing on lack of a contamination. |
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5. By the indicator of hour type measure palpation of primary and secondary shaft. Palpation: 0,015 mm
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Prevention
If replacement of a secondary shaft was carried out, adjust a preliminary tightness of the bearing.
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Oil gap, mm
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Element
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Shaft (external diameter)
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Gear wheel (internal diameter)
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gap
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The 1st
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39,445–39,470
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39,500–39,525
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0,03–0,08
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The 2nd
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35,145–35,170
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47,009–47,025
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Assembly
NAVE OF THE COUPLING OF THE SYNCHRONIZER
| PERFORMANCE ORDER |
| Establish clamp and spring crackers in a nave of the coupling of the synchronizer. |
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Sizes of a cracker of a clamp, mm
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Element
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1
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2
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3
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1-ая/the 2nd
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18,0
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4,25
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5,0
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3-ья/the 4th
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17,0
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4,25
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5,0
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4-ая/Z.Kh.
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17,0
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4,25
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5,0
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THE BEARING (FROM DIFFERENTIAL)
| PERFORMANCE ORDER |
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Using a press and the special AA1 adaptation OK900 175 establish the new bearing. |
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GEAR WHEEL OF THE 1ST TRANSFER, RING OF THE SYNCHRONIZER OF THE 1ST TRANSFER AND SYNCHRONIZER 1-ОЙ/OF THE 2ND TRANSFER
Prevention
On a ring of the synchronizer of the 2nd transfer there are no teeths in three places on perimeter to distinguish it from other rings of the synchronizer.
| PERFORMANCE ORDER |
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1. Establish a gear wheel of the 1st transfer, a ring of the synchronizer of the 1st transfer and the synchronizer 1-ой/of the 2nd transfer how it is shown in drawing. |
| 2. Combine dredging of a ring of the synchronizer with clamp crackers. |
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3. Using a press and the special AA1 adaptation OK900 175 establish a nave of the coupling of the synchronizer 1-ой/of the 2nd of transfers. |
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RING OF THE SYNCHRONIZER OF THE 2ND TRANSFER AND GEAR WHEEL OF THE 2ND AND 3RD TRANSFERS
| PERFORMANCE ORDER |
| 1. Establish a ring of the synchronizer of the 2nd transfer and a gear wheel of the 2nd transfer. |
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2. Using a press and the special AA1 adaptation OK900 175 establish a gear wheel of the 3rd transfer. |
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GEAR WHEEL OF THE 4TH TRANSFER AND INTERNAL RING OF THE BEARING
| PERFORMANCE ORDER |
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1. Using a press and the special AA1 adaptation OK900 175, establish a gear wheel of the 4th transfer and an internal ring of the bearing. |
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2. Measure a gap between a gear wheel of the 1st transfer and a gear wheel of a drive of differential. Nominal gap: 0,05–0,28 mm
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3. Measure a gap between a gear wheel of the 2nd and 3rd transfers. Nominal gap: 0,10–0,22 mm
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| 4. If gaps do not correspond demanded, disassemble and repeatedly collect a secondary shaft. |
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