LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Kia >> 2007 >> Rio Base, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - M/T >> Manual Transaxle System >> Input Shaft >> Reassembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Input Shaft: Reassembly

  1. Install the 3rd needle bearing (A) on the input shaft (B).
    Fig 1: Locating 3rd Needle Bearing And Input Shaft
    G04864833Courtesy of KIA MOTORS AMERICA, INC.
  2. Apply transaxle oil to the needle bearing.
  3. Install the 3rd gear (A).
    Fig 2: Locating 3rd Gear
    G04864834Courtesy of KIA MOTORS AMERICA, INC.
  4. Install the 3rd inner synchronizer ring (A). (Double cone type)
    Fig 3: Locating 3rd Inner Synchronizer Ring
    G04864835Courtesy of KIA MOTORS AMERICA, INC.
  5. Install the 3rd synchronizer cone (B).
  6. Install the 3rd outer synchronizer ring (C).
    NOTE: Pay attention the direction of protrusion of a synchronizer ring.
    Fig 4: Checking Direction Of Protrusion Of Synchronizer Ring
    G04864836Courtesy of KIA MOTORS AMERICA, INC.
  7. Assemble the 3rd & 4th synchronizer hub (A) using press.
    NOTE:
    • When installing the synchronizer hub, make sure that the fingers of synchronizer ring are seated correctly in its groove on the synchronizer hub.
    • After installation of the synchronizer hub, check that synchronizer hub rotates smoothly.
      Fig 5: Identifying Synchronizer Hub
      G04864837Courtesy of KIA MOTORS AMERICA, INC.
  8. Install the synchronizer keys (A).
    Fig 6: Identifying Synchronizer Keys
    G04864838Courtesy of KIA MOTORS AMERICA, INC.
  9. Install the 3rd & 4th synchronizer sleeve.
    NOTE:
    • Put down the 3rd slope face of sleeve with the identification mark.
    • Make sure that the groove of sleeve inside is seated correctly in the groove of synchronizer hub.
      Fig 7: Identifying Synchronizer Sleeve
      G04864839Courtesy of KIA MOTORS AMERICA, INC.
      Fig 8: Checking Groove Of Sleeve Inside
      G04864840Courtesy of KIA MOTORS AMERICA, INC.
  10. Install the 4th outer synchronizer ring (A).
    NOTE: When installing the synchronizer ring, make sure that the fingers of synchronizer ring are seated correctly in the grooves of the 3rd & 4th synchronizer hub.
    Fig 9: Identifying Synchronizer Ring Position
    G04864841Courtesy of KIA MOTORS AMERICA, INC.
    Fig 10: Identifying Outer Synchronizer Ring
    G04864842Courtesy of KIA MOTORS AMERICA, INC.
  11. Install the 4th gear sleeve (A) using press.
    Fig 11: Identifying Gear Sleeve
    G04864843Courtesy of KIA MOTORS AMERICA, INC.
  12. Install the 4th needle bearing (A).
    Fig 12: Identifying Needle Bearing
    G04864844Courtesy of KIA MOTORS AMERICA, INC.
  13. Apply transaxle oil to the needle bearing.
  14. Install the 4th gear (A).
    Fig 13: Identifying Gear
    G04864845Courtesy of KIA MOTORS AMERICA, INC.
  15. Install the 5th sleeve (A) using press.
    Fig 14: Identifying Sleeve
    G04864846Courtesy of KIA MOTORS AMERICA, INC.
  16. Install the 5th needle bearing (A).
    Fig 15: Identifying Needle Bearing
    G04864847Courtesy of KIA MOTORS AMERICA, INC.
  17. Install the 5th gear (A).
    Fig 16: Identifying Gear
    G04864848Courtesy of KIA MOTORS AMERICA, INC.
  18. Install the 5th synchronizer ring (A).
    Fig 17: Identifying Synchronizer Ring
    G04864849Courtesy of KIA MOTORS AMERICA, INC.
  19. Install the 5th synchronizer hub (A) using the press.
    NOTE:
    • When installing hub, make sure the direction as shown in the picture.
    • When pressing the hub, make sure that the fingers of the 5th synchronizer ring (double cone) are seated correctly in the grooves of the hub.
      Fig 18: Identifying Spacer
      G04864850Courtesy of KIA MOTORS AMERICA, INC.
      Fig 19: Identifying Synchronizer Hub
      G04864851Courtesy of KIA MOTORS AMERICA, INC.
  20. Install the synchronizer key (A).
    Fig 20: Identifying Synchronizer Keys
    G04864838Courtesy of KIA MOTORS AMERICA, INC.
  21. Install the 5th synchronizer sleeve.
    NOTE:
    • Put down the 5th slope face of sleeve with the identification mark.
    • Make sure that the groove of sleeve inside is seated correctly in the groove of synchronizer hub.
      Fig 21: Identifying Synchronizer Sleeve
      G04864839Courtesy of KIA MOTORS AMERICA, INC.
      Fig 22: Checking Groove Of Sleeve Inside
      G04864854Courtesy of KIA MOTORS AMERICA, INC.
  22. Install the spacer (A) and ring (B).
    Fig 23: Identifying Spacer And Ring
    G04864855Courtesy of KIA MOTORS AMERICA, INC.
  23. Install the spacer (A).
    Fig 24: Identifying Spacer
    G04864856Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: When installing the spacer, make sure that three fingers of spacer are seated correctly in three grooves of 5th synchronizer hub.
    Fig 25: Identifying Synchronizer Hub Grooves
    G04864857Courtesy of KIA MOTORS AMERICA, INC.
  24. Install the thrust washer.
  25. Install the ball bearing (A) by press and special tool (09432-33300).
    Fig 26: Identifying Ball Bearing And Special Tool (09432-33300)
    G04864858Courtesy of KIA MOTORS AMERICA, INC.
  26. Install the snap ring.
  27. Install the front input shaft ball bearing by press and special tool (09432-33300).
  28. Install the snap ring (A).
    Fig 27: Identifying Snap Ring
    G04864859Courtesy of KIA MOTORS AMERICA, INC.
scientia non olet · About LEMON Manuals