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Home › Kia › 2007 › Spectra5 2.0 1, Standard › Repair and Diagnosis › Transmission › Manual Trans › Overhaul › Manual Transaxle System › Output Shaft › Reassembly

Output Shaft: Reassembly

  1. Install the first speed gear assembly with needle bearing.
    Fig 1: Installing First Speed Gear
    G00333323Courtesy of KIA MOTORS AMERICA, INC.
  2. Combine the first-second gear synchronizer hub and sleeve.
    Fig 2: Combining First-Second Gear Synchronizer Hub And Sleeve
    G00333324Courtesy of KIA MOTORS AMERICA, INC.
  3. The synchronizer sleeve has teeth missing at six places.

    Assemble the hub to the sleeve so that the center tooth between the two missing teeth will touch the synchronizer key.

    Fig 3: Assembling Synchronizer Hub To Sleeve
    G00333325Courtesy of KIA MOTORS AMERICA, INC.
  4. Install the synchronizer spring so that its protrusion may be engaged in the groove of the synchronizer keys.
    CAUTION: When installing the synchronizer springs, make sure they are not facing the same direction.
    Fig 4: Installing Synchronizer Spring
    G00333326Courtesy of KIA MOTORS AMERICA, INC.
  5. Install the first-second speed gear synchronizer assembly over the output shaft using the special tool (09432-22000).
    CAUTION:
    • When installing the synchronizer assembly, make sure that the three synchronizer keys are seated correctly in their respective groove on the synchronizer ring.
    • After installation of the synchronizer assembly, check that first gear rotates smoothly.
      Fig 5: Installing First-Second Speed Gear Synchronizer Assembly
      G00333327Courtesy of KIA MOTORS AMERICA, INC.
  6. Install the second speed gear with needle roller bearing and bearing sleeve using the special tool (09432-22000).
    Fig 6: Installing Second Speed Gear With Needle Roller Bearing And Bearing Sleeve
    G00333328Courtesy of KIA MOTORS AMERICA, INC.
  7. Install the third speed gear and spacer.
    Fig 7: Installing Third Speed Gear And Spacer
    G00333329Courtesy of KIA MOTORS AMERICA, INC.
  8. Install the fourth speed gear using the special tool (09432-22000).
    Fig 8: Installing Fourth Speed Gear
    G00333330Courtesy of KIA MOTORS AMERICA, INC.
  9. Install the bearing using the special tool (09432-22000).
    CAUTION: Do not reuse the bearing removed from the shaft.
    Fig 9: Installing Bearing
    G00333331Courtesy of KIA MOTORS AMERICA, INC.
  10. Install the rear side taper roller bearing using the special tool (09432-22000).
    Fig 10: Installing Rear Side Taper Roller Bearing
    G00333332Courtesy of KIA MOTORS AMERICA, INC.
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