PREASSEMBLY Bearing Preload & Adjustments: Notes

When replacing any of parts listed in table shown in illustration, adjust bearing preload by selecting and installing proper adjustment shim (s).

1. Install primary and secondary shaft bearing races into transaxle case (diaphragm springs and shims removed).
2. Mount clutch housing onto transaxle hanger, and set differential bearing race into clutch housing. Position piece of pipe against bearing race and tap it in until it contacts clutch housing.
3. Set bearing races into SST (OK900 175 A01/K94A-4200-TI/OK900 175 A02/K94A-4200-T2/OK900 175 A03/K94A-4200-T3)  as shown in figure.
4. Turn selector to eliminate gap indicated by arrow.
   Fig 4: Adjusting Selector Gap

   Courtesy of KIA MOTORS AMERICA, INC.
5. Set differential assembly into clutch housing, and set bearing race and SST (OK900 175 A03/K94A-4200-T3)  on differential. Set assembled selectors for primary and secondary shaft in clutch housing. Mount shaft gear assemblies as shown in figure.
   Fig 5: Mounting Shaft Gear Assemblies

   Courtesy of KIA MOTORS AMERICA, INC.
6. Set SST (OK130 175 A02/213228)  in positions shown in figure.
   Fig 6: Setting Service Tools

   Courtesy of KIA MOTORS AMERICA, INC.
7. Install transaxle case and tighten SST (OK130 191 A07/210590)  to specified torque.

   Tightening torque: 28~38 lb. ft (38~51 N.m, 3.8~5.3 kg.m) 

   Fig 7: Installing Transaxle Case

   Courtesy of KIA MOTORS AMERICA, INC.
8. To seat bearings, mount SST (OK130 175 A03/213229)  on parts A and B of selectors, and turn selectors so gaps are widened. Then turn SST (0K130 175 A03/213229)  in reverse direction until gaps are eliminated.
   Fig 8: Seating Bearings

   Courtesy of KIA MOTORS AMERICA, INC.
9. Manually expand selector until it no longer turns by hand.
10. Verify that both primary and secondary shafts turn smoothly.
    Fig 9: Verifying That Both Primary And Secondary Shafts Turn Smoothly

    Courtesy of KIA MOTORS AMERICA, INC.
11. Measure clearance between two halves of SST (OK900 175 A01 / K94A-4200-T1)  around circumference by using feeler gauge.
12. Take maximum reading and determine shim to be used. Use no more than two shims.
    Fig 10: Measuring For Shim Thickness

    Courtesy of KIA MOTORS AMERICA, INC.

Primary shaft adjustment shim 

• Subtract diaphragm spring thickness (0.026 in {0.65 mm}) from gap determined in Step  11 for primary shaft.
• Make shim selection range by subtracting standard clearance parameters from result in previous step.
• Select thinner shim within range to obtain standard clearance.

Standard clearance 0~0.002 in (0~0.05 mm) 

1. Example: 0.048 in (1.22 mm) - 0.026 in (0.65 mm) = 0.022 in (0.57 mm) 
2. Shim selection range: (0.022 in (0.57 mm) - 0.002 in (0.05 mm))= (0.022 in (0.57 mm) - 0 mm (0 in))= 0.020 in (0.52 mm) ~ 0.022 in (0.57 mm) 
3. Shim: 0.022 in (0.55 mm) 
   Fig 11: Shim Thickness Chart

   Courtesy of KIA MOTORS AMERICA, INC.

Secondary shaft adjustment shim 

• Make shim selection range by adding standard clearance parameters to result in previous step.
• Select thinner shim within range to obtain standard clearance.

  Tightening amount: 0.001~0.003 in (0.03~0.08 mm) 

  1. Shim selection range: (0.022 in (0.57 mm) + 0.001 in (0.03 mm)) (0.022 in (0.57 mm) + 0.003 in (0.08 mm)) = 0.020 in (0.52 mm) - 0.022 in (0.57 mm) = 0.024 in (0.60 mm) ~ 0.026 in (0.65 mm) Shim: 0.024 in (0.60 mm) 
  2. Install SST (OK130 191 A05 / K94A-4200-T4) to differential.
  Fig 12: Installing Service Tool

  Courtesy of KIA MOTORS AMERICA, INC.
• Turn SST (OK130 322 020)  with torque wrench. Adjust SST (OK900 175 A01/K94A-4200-T1)  with SST (OK130 175 A03/213229)  until specified preload is obtained.

  Preload: 12.15~17.36 lb. in (1.37~1.96 N.m 14~20 kg-cm) 

  Fig 13: Measuring Bearing Preload

  Courtesy of KIA MOTORS AMERICA, INC.
• Measure gap between A and B around circumference of SST (OK900 175 A01/K94A-4200-T1)  by using feeler gauge.
• Add 0.006 in (0.15 mm) to measured clearance and select combination of two shims closest in value to that measurement. Use no more than two shims.
  Fig 14: Measuring For Shim Thickness

  Courtesy of KIA MOTORS AMERICA, INC.
  1. Example: 0.013 in (0.32 mm) 
     1. 0.013 in (0.32 mm) + 0.006 in (0.15 mm) = 0.019 in (0.47 mm). 
  2. Nearest shim (on thick side) to 0.019 in (0.47 mm) is 0.020 in (0.50 mm). 
• Remove transaxle case and SST (OK900 175 AAO/K94A-4200-T). 
• Remove selectors, primary shaft assembly and the differential.
• Remove bearing races.