Kia Carnival Cambio

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2008 > HTX > HTX > Manual Transaxle System > Manual Transaxle System > Manual TransaxleEnglish
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Components and Components Location (HTX)
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SECTION VIEW
COMPONENTS
https://www.kia-hotline.com/manualV2/content/view?printFlag=0&oriMnuKCd=OV... 02/03/2022
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2008 > HTX > HTX > Manual Transaxle System > Manual Transaxle System > Manual Transaxle >
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Repair procedures (HTX)
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DISASSEMBLY
1. Remove the rear cover.
2. Remove the lock nut and retainer ring.
3. Remove the detent plug, the spring, the back-up lamp switch and the steel ball.
4. Remove the reverse idler gear bolt.
5. Remove the transaxle case bolts.
6. Remove the transaxle case using the special tool.
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7. Remove the reverse shift lever, the reverse lever spring set, stopper body, the reverse idler shaft and gear.
8. Using a pin punch, remove the 5th shift fork mounting spring pin and 5th&reverse shift lug mounting spring pin.
After removing the 5th&reverse shift rail, remove the 5th&reverse shift fork and shift lug.
Discard spring pin.
9. Using a pin punch, remove the 3rd&4th shift fork mounting spring pin and 3rd&4th shift lug mounting spring pin.
After removing the 3rd&4th shift rail, remove the 5th shift fork, 3rd&4th shift fork and 3rd&4th shift lug at the same
time.
Discard spring pin.
10. Using a pin punch, remove the 1st&2nd shift fork mounting spring pin and 1st&2nd shift lug mounting spring pin.
After removing the 1st&2nd shift rail, remove the 1st&2nd shift fork and 1st&2nd shift lug at the same time.
Discard spring pin.
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11. Remove the snap ring for the input shaft rear ball bearing.
12. Remove the input shaft rear ball bearing and 5th gear assembly at the same time using the general tool.
13. Remove the output shaft spacer and the shim.
14. After removing the 4th/5th gear retainer ring, remove the output shaft 4th/5th gear using the general tool.
15. Remove the input shaft side synchronizer sleeve and 4th gear using the general tool.
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16. Remove the input shaft snap ring for the clutch hub.
17. Using the general tool, remove the input shaft side 3rd gear, synchronizer ring, synchronizer hub and needle
bearing at the same time.
18. Remove the output shaft 2nd/3rd gear using the general tool.
19. Remove the output shaft needle bearing and spacer.
20. Remove the output shaft 2nd synchronizer inner ring and double cone.
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21. Remove the 1st&2nd synchronizer key and sleeve.
22. Using the general tool, pull up the 1st gear assembly.
After pulling up the 1st gear, remove the spacer, hub and double cone at the same time.
23. Remove the output shaft bearing retainer cover using the hexagonal wrench.
Securely seat the removal tool to the groove of retainer screw using a hammer or equivalent and then
remove the retainer.
24. Remove the output shaft.
Intermittently seat the case and tighten the nut, and then remove the output shaft using a proper tool as
shown in the illustration.
25. After removing the speedometer driven gear, remove the differential assembly.
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Lay down the clutch housing aslant and then remove the differential.
26. Remove the input shaft oil seal with a screwdriver or suitable tool.
27. Remove the differential oil seal with a screwdriver or a suitable tool.
(Seal must be replaced everytime/soft part replacement).
28. Remove the bearing outer race with a suitable tool and only if the bearing replacement is necessary.
29. Remove the output shaft outer race and spacer shim of the transaxle case with a screwdriver or suitable tool.
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EXPLANATION OF END PLAY ADJUSTMENT (FOR SOLDER CRUSH)
1) Indicates tightening of - (minus) direction of endplay.

2) It means that this end play can't be seen (Tightening
condition).
3) For example:
T
0.05T is the condition of endplay which receive -
(TIGHT)
(minus) force pressure to - (minus) 0.05mm.
4) You can adjust this minus condition of end play using
thicker shim.
5) However this end play can't be measured by gauge.
1) Indicates loosening of + (plus) direction of end play

(Normal endplay).
2) It means that this end play can be seen which have
L
allowances.
(LOOSE)
3) For example:
0.05L is the condition of end play which have
allowance up to 0.05mm (Normal endplay).
When repairing transaxle, generally you should use shim to meet specification.
Because of wearing of shim, end play might be bigger.
SERVICE TIP
• The choice of standard shim
Differential bearing end play
The value of end play measured by solder thickness is 0.9mm, please refer to following method for choosing the
standard shim.
1) Standard value of end play (mm): 0.1T - 0.2T (mm)
2) The range of correct spacer: 0.9 - (-0.1) - 0.9 - (-0.2) = 1.0 - 1.1
3) From "DIFFERENTIAL BEARING SHIM TABLE" in this manual, select a shim that is equal to the correct shim
thickness or use the next smaller shim in the table.
4) The types of shim for adjustment of differential bearing end play are as follows;
(0.71....., 1.07, 1.10, 1.13, 1.19)
5) You should choose the shim of 1.10mm for adjustment of differential bearing end play.
REASSEMBLY
1.
Install the special tool to the clutch housing after removing the sealing cap to absorb shock and prevent damage of
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the clutch housing, while installing the input shaft and the output shaft using a press.
2. Install the new oil seal to the transaxle case using the special tool.
3. Shim selection for differential bearing.

(1) Height gauge method
• There are 2 methods as selecting shim for differential bearing.

• One is the method by the height gauge, the other is one by solder crush.
a. After installing the differential assembly to the clutch housing, measure the length (A) between the sealing
surface of the clutch housing (Figure 1) and the differential outer race (Figure 2) using the height gauge.
b. Measure the length (B) between the sealing surface of the transaxle case (Figure 3) and the seated
surface of the outer race (Figure 4) on the transaxle case using the height gauge.
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Standard value B : 9.46 ± 0.05mm
c. Shim selection
Shim thickness: B - A - (Differential endplay value)
Standard differential end play: -0.05 ~ -0.10mm
(2) Solder crush method

a. Place the solder on the transaxle case as illustrated.
b. Install the differential bearing outer race on the transaxle case.
c. Install the transaxle case temporarily and tighten the bolts to the specified torque, then remove the
transaxle case.
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d. Detach the crushed solder.

e. Measure the thickness of the crushed solder.
Refer to the "EXPLANATION OF ENDPLAY ADJUSTMENT' to select the shim for the differential
bearing.
DIFFERENTIAL BEARING SHIM TABLE

Part number Shim thickness (mm)
43331-39071 0.71
43331-39074 0.74
43331-39077 0.77
43331-39080 0.80
43331-39083 0.83
43331-39086 0.86
43331-39089 0.89
43331-39092 0.92
43331-39095 0.95
43331-39098 0.98
43331-39101 1.01
43331-39104 1.04
43331-39107 1.07
43331-39110 1.10
43331-39113 1.13
43331-39116 1.16
43331-39119 1.19
4. Install the new adjustment shim and apply the transaxle oil to the bearing outer race, and install it to the transaxle
case using the special tool.
5. Install the differential into the clutch housing.
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6. Install new oil seal using a suitable tool.
7. Apply the transaxle oil to the input shaft oil seal, and install it to the clutch housing using the suitable tool.
8. After installing the speedometer driven gear, install the output shaft.
9. Install the output shaft bearing retainer using the hexagonal wrench.
Securely seat the installation tool to the groove of retainer screw using a hammer or equivalent and then
install the retainer.
TORQUE :
38~50Nm (380~500kgf·cm, 27~36lbf·ft)
10. Install the output shaft clutch hub and 1st gear using the special tool while installing the input shaft at the same
time.
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DETAIL COMPONENT
a. Needle bearing
b. 1st gear
c. Synchronizer inner ring
d. Double cone
e. Synchronizer ring
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f. Clutch hub (SST P/No.: 09432-3A100)
The hub side with 4 oil groove should face the 1st gear side.
g. Bearing collar (SST P/No.: 09432-3A100)
h. Output shaft synchronizer ring and key spring.
i. Output shaft synchronizer inner ring, double cone and spacer.
11. Install the output shaft needle bearing. English 
12. Install the output shaft 2nd/3rd gear using the special tool.
13. Install the input shaft side 3rd gear assembly as shown.
14. Install the 3rd gear needle bearing.
15. Sub-assemble the 3rd/4th synchronizer hub & sleeve, key and synchronizer ring.
16. Using the special gear installer (P/No.: 09432-3A100), install the sub-assembled 3rd&4th synchronizer hub&sleeve
on the input shaft.
Be sure to hold the hub & sleeve with a hand to prevent the synchronizer key from separating while installing.
The hub side with 4 oil grooves should face the 3rd gear side.
17. Install the input shaft retainer.
18. Install the input shaft side 4th speed gear.
19. Install the 4th speed gear needle bearing.

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20. Install the output shaft 4th/5th gear using the special tool.
The 5th gear side with 2 oil grooves should face the 4th gear side.
21. Install the input shaft 4th gear sleeve, 4th gear and needle bearing using the special tool.
22. Install the 5th gear retainer.
23. Install the input shaft side 5th speed gear and needle bearing.
24. Using the special gear installer (P/No.: 09432-3A100), install the sub-assembled 5th synchronizer hub&sleeve on
the input shaft.
Be sure to hold the hub&sleeve with a hand to prevent the synchronizer key from separating while installing.
The hub side with 3 oil groove should face the upper side.
25. Install the input shaft clutch hub sleeve. English 
26. Install the input shaft synchronizer ring.
27. Using the special gear installer (P/No.: 09432-3A100), install the input shaft reverse brake cone.
28. Install the input shaft reverse cone sleeve.
29. Install the input shaft rear ball bearing using the special tool.
30. Install the snap ring for the input shaft rear ball bearing.
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31. Install the 1st/2nd shift rod, fork and rod end.
32. Install the 3rd/4th shift rod, fork and rod end.
33. Install the 5th/Rev. shift rod, fork and rod end.
34. Install the reverse shift lever, the reverse lever spring set, the reverse idler shaft, stopper body assembly and gear.
35. Shim selection for input shaft

• There are 2 methods as selecting shim for input shaft.
• One is the method by the height gauge, the other is one by solder crush.
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(1) Height gauge method

a. Measure the 'C' dimension of the transaxle case using the height gauge.
C = C' - C"
a. Measure the length (D) between the sealing surface of the clutch housing (Figure 5) and the input shaft
rear ball bearing (Figure 6) using the height gauge.
Standard value D: 239.87mm ~ 240.0mm
b. Shim selection
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Shim thickness: (D-C) - (input shaft end play value)
Standard input shaft end play: 0~0.1mm
(2) Solder crush method

a. Place the solder on the input shaft bearing as illustrated.
b. Install the transaxle case and the taper roller bearing.
c. Install the lock nut.
d. Be sure that the solder is well installed between the transaxle case and the input shaft bearing.
e. Tighten the lock nut and the bolts, then remove the transaxle case.
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f. Detach the crushed solder.

g. Measure the thickness of the crushed solder.
Refer to the "EXPLANATION OF ENDPLAY ADJUSTMENT" to select the shim for the input shaft.
INPUT SHAFT SHIM TABLE

43217-3A000 0.20
43217-3A001 0.15
43217-3A002 0.30
43217-3A003 0.10
36. Shim selection for output shaft

a. Install the old shim and the transaxle case temporarily.
b. Tighten the output shaft side lock nut and install the dial gauge.
c. Move up and down the output shaft and measure the output shaft end play using a proper tool as shown in
the illustration.
Remove the lock nut and then discard it.
Standard output shaft end play: 0.03 ~ 0.1mm
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OUTPUT SHAFT SHIM TABLE

43348-3A001 0.10
43348-3A002 0.12
43348-3A003 0.15
43348-3A004 0.16
43348-3A005 0.18
43348-3A006 0.20
43348-3A007 0.30
43348-3A008 0.40
43348-3A009 0.50
43348-3A010 0.25
43348-3A011 0.35
37. After removing the transaxle case, install the new adjustment shim(s) to the input and output shaft bearing seats in
the transaxle case. And apply the transaxle oil to each bearing race, and install them to the transaxle case using
the suitable tool.
38. Install the transaxle case and clutch housing after sealing surface.
39. While installing the transaxle case, align holes in the case and reverse idler shaft.
40. Install the reverse idler gear bolt.
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41. Install the detent plug, the spring, the back-up lamp switch, the steel ball, the lock nut and the snap ring.
Lock the nut using chisel not to rotate.
42. Completely remove sealant on the rear cover sealing surface and reseal the rear cover.
Install the rear cover.
43. Remove the clutch housing support. (P/No. : 09431-3A100)
44. Install the new sealing cap.
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1. Remove the rear cover.

2. Remove the lock nut and retainer ring.

4. Remove the reverse idler gear bolt.

5. Remove the transaxle case bolts.

6. Remove the transaxle case using the special tool.

13. Remove the output shaft spacer and the shim.

19. Remove the output shaft needle bearing and spacer.

21. Remove the 1st&2nd synchronizer key and sleeve.

24. Remove the output shaft.

EXPLANATION OF END PLAY ADJUSTMENT (FOR SOLDER CRUSH)

1) Indicates tightening of - (minus) direction of endplay.

1) Indicates loosening of + (plus) direction of end play

3. Shim selection for differential bearing.

• There are 2 methods as selecting shim for differential bearing.

Standard value B : 9.46 ± 0.05mm

(2) Solder crush method

b. Install the differential bearing outer race on the transaxle case.

d. Detach the crushed solder.

DIFFERENTIAL BEARING SHIM TABLE

5. Install the differential into the clutch housing.

6. Install new oil seal using a suitable tool.

c. Synchronizer inner ring

f. Clutch hub (SST P/No.: 09432-3A100)

g. Bearing collar (SST P/No.: 09432-3A100)

h. Output shaft synchronizer ring and key spring.

i. Output shaft synchronizer inner ring, double cone and spacer.

11. Install the output shaft needle bearing. English 

14. Install the 3rd gear needle bearing.

17. Install the input shaft retainer.

18. Install the input shaft side 4th speed gear.

19. Install the 4th speed gear needle bearing.

22. Install the 5th gear retainer.

25. Install the input shaft clutch hub sleeve. English 

26. Install the input shaft synchronizer ring.

28. Install the input shaft reverse cone sleeve.

35. Shim selection for input shaft

(1) Height gauge method

Standard value D: 239.87mm ~ 240.0mm

(2) Solder crush method

b. Install the transaxle case and the taper roller bearing.

c. Install the lock nut.

f. Detach the crushed solder.

INPUT SHAFT SHIM TABLE

36. Shim selection for output shaft

OUTPUT SHAFT SHIM TABLE

40. Install the reverse idler gear bolt.

43. Remove the clutch housing support. (P/No. : 09431-3A100)

44. Install the new sealing cap.

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