Repair of Kia Magentis gearbox shafts

Disassembling the gearbox shafts to replace parts

Disassembling and assembling the gearbox input shaft

Using puller 09432-21300, remove the spring ring and ball bearing

Remove the snap spring ring, snap ring, fifth and fourth gear pinions, needle bearing, fourth gear pinion bushing, third and fourth gear synchronizer ring, first, second, third, fourth gear synchronizer springs, third and fourth gear synchronizer bushings, gear third gear and needle bearing

Checking

Checking the surface of the input shaft that contacts the needle bearings for damage or wear

Checking the shaft splines for damage or wear

Install the synchronizer sleeve on the sleeve and make sure it moves smoothly

Check the sleeve for damage

Check the wear of the sleeve end surfaces (in contact with each gear)

Assembly

Using a special tool 09432-33300 we install a needle bearing, a third gear pinion, a third and fourth gear synchronizer sleeve, 1st-4th gear synchronizer springs, a third and fourth gear synchronizer ring, a fourth gear pinion sleeve, a needle bearing, fifth and fourth gear pinions, a retaining ring and a retaining spring ring

Using a special tool 09432-21300 we install a ball bearing and a spring ring

Disassembling and assembling the driven shaft of the gearbox

The figure shows the assembly sequence of the gearbox driven shaft

Removing the retaining ring

Using special tool 09432-33000 we remove ball bearing and gear reverse

Remove the synchronizer ring, the synchronizer spring of the fifth gear and reverse gear, the fifth gear and reverse gear sleeve

Using special tool 09432-33000, remove the synchronizer sleeve and the fifth gear pinion

Using special tool 09432-33200, remove the gears of 4th, 3rd, 2nd, and first gears together

Checking

Checking the surface of the driven shaft in contact with the needle bearings for damage and wear

Check the shaft splines for damage and wear

Install the needle bearing with the support sleeve and gear on the shaft.

Check that the bearing rotates evenly without noise or play

Check the needle bearing housing for damage

Inspect the synchronizer ring teeth for damage

Check the inner surface for damage, wear, or groove damage

Install the synchronizer sleeve on the sleeve and make sure it moves smoothly

Check the sleeve for wear and damage

Checking the wear of the bushing end surfaces that contact each gear

Checking the gear teeth for wear and damage

Checking the conical surface of the gear for roughness, damage and wear

Checking the gear bore for wear and damage

Assembly

Installing a needle bearing

Installing a first gear pinion

Installing the locking cone ring

Installing the synchronizer sleeve and sleeve

Installing the locking cone ring

Installing the second gear sleeve and needle bearing

Using a special tool 09432-22000, we install the second and third gear pinion

We install retaining ring

We install the fourth gear pinion, the fifth gear pinion sleeve, the needle bearing, the fifth gear pinion, the fifth gear synchronizer ring, the synchronizer sleeve and the fifth gear and reverse gear sleeve

Installing the needle bearing, reverse gear and driven gear bushing

Using special tool 09432-22000, install the ball bearing and retaining ring