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Input Shaft: Reassembly

  1. Install the synchronizer hub and sleeve so that they are positioned as shown in the figure.
    Fig 1: Positioning Synchronizer Hub & Sleeve
    G00178802Courtesy of KIA MOTORS AMERICA, INC.
  2. 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 synchronizer key.

    Fig 2: Assembling Synchronizer Hub To Sleeve
    G00333301Courtesy of KIA MOTORS AMERICA, INC.
  3. Install the synchronizer spring so that the stepped portions will rest on the synchronizer keys.
    CAUTION: When installing the synchronizer springs, make sure they are not facing the same direction.
    Fig 3: Identifying Synchronizer Spring
    G00333302Courtesy of KIA MOTORS AMERICA, INC.
  4. Install the 3rd-4th gear synchronizer assembly on the input shaft using the special tool (9432-22000).
    WARNING:
    • When installing the synchronizer assembly, make sure that the three synchronizer keys are seated correctly in their respective grooves of the synchronizer ring.
    • After installing the synchronizer assembly, check that 3rd gear rotates smoothly.
      Fig 4: Installing Synchronizer Assembly
      G00333309Courtesy of KIA MOTORS AMERICA, INC.
  5. Install the bearing sleeve using the special tool (09432-33300).
    Fig 5: Installing Bearing Sleeve
    G00333310Courtesy of KIA MOTORS AMERICA, INC.
  6. Install the needle bearing and 4th gear on the input shaft.
  7. Install the spacer and sleeve on the input shaft.
    Fig 6: Installing Spacer On Input Shaft
    G00333311Courtesy of KIA MOTORS AMERICA, INC.
  8. Install the ball bearing on the input shaft using the special tool (9432-22000).
    Fig 7: Installing Ball Bearing On Input Shaft
    G00333312Courtesy of KIA MOTORS AMERICA, INC.