Output Shaft: Reassembly

Install the needle bearing (A).

Fig 1: Identifying Needle Bearing
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Apply the MT oil to the needle bearing.
Install the 1st gear (A).

Fig 2: Identifying Gear
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Install the 1st inner synchronizer ring (A).

Fig 3: Identifying Inner Synchronizer Ring
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Install the 1st synchronizer cone (B).
Install the 1st outer synchronizer ring (C).
Install the 1st & 2nd synchronizer hub using press.
NOTE: When installing hub, make sure that the fingers of 1st synchronizer ring are seated correctly in the grooves of synchronizer hub.

Fig 4: Identifying Synchronizer Cone
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NOTE: When installing hub, make sure the direction as shown in the picture.

Fig 5: Identifying Hub
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Install the synchronizer key (A).

Fig 6: Identifying Synchronizer Key
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Install the 1st & 2nd sleeve (A).

Fig 7: Identifying 1st & 2nd Sleeve
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Install the 2nd sleeve using press.

Fig 8: Identifying 2nd Sleeve
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Install the 2nd outer synchronizer ring (A). (Trifle cone)

Fig 9: Identifying Outer Synchronizer Ring
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Install the 2nd synchronizer cone (B).
Install the 2nd inner synchronizer ring (C).
Install the 2nd needle bearing (A).

Fig 10: Identifying 2nd Needle Bearing
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Install the 2nd gear (A).

Fig 11: Identifying Gear
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Install the 3rd (A), 4th (B) and 5th (C) gear using press. (09432-21500)
NOTE: Heat the 3rd gear with electrical heater before using press.

Fig 12: Heating Gear With Electrical Heater
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Fig 13: Identifying Gears And Press (09432-21500)
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Install the spacer using press and special tool (09455-21100).
Install the rear taper roller bearing using press and special tool (09432-22000).
NOTE: Do not reuse the removed bearing.

Fig 14: Identifying Special Tool (09432-22000)
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Install the opposite side taper roller bearing using press and special tool (09432-22000).
NOTE: Do not reuse the removed bearing.

Fig 15: Installing Opposite Side Taper Roller Bearing Using Press And Special Tool (09432-22000)
Courtesy of KIA MOTORS AMERICA, INC.