Manual Trans: Overhaul: Components: Differential: Reassembly

Install the spacer on the back of the side gear and then install the gear in the differential case.

Fig 1: Installing The Gear In The Differential Case
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
1. When installing a new side gear, use a spacer of medium thickness [0.93-1.00 mm (0.036-0.04 in.)].
2. Do not reuse the lock pin.
3. The lock pin head must be sunk below the flange surface of the differential case.
Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears by turning them.
Insert the pinion shaft.

Fig 2: Inserting The Pinion Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Measure the backlash between the side gears and pinions.
Standard value: 0.025-0.150 mm (0.00095-0.0057 in.)

Fig 3: Measuring The Backlash
Courtesy of KIA MOTORS AMERICA, INC.
If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.
CAUTION: Adjust the backlash of both side gears to the same specification.
Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.

Fig 4: Inserting The Lock Pin
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
1. Do not reuse the lock pin.
2. The lock pin head must not protrude more than 3 mm (0.118 in.).
Install the taper roller bearings on both sides of the differential case using the special tool (09455-21100).
CAUTION: When press fitting the bearing, press on the inner race only.

Fig 5: Installing The Taper Roller Bearings
Courtesy of KIA MOTORS AMERICA, INC.
Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the illustration.
Specified sealant: Three bond 1303

CAUTION: If a bolt is reused, remove the old sealant from the threads.

Fig 6: Tightening Drive Retaining Bolts
Courtesy of KIA MOTORS AMERICA, INC.