Diagnosis & 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 Gear In To Differential Case
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
1. When installing a new side gear, use a spacer of medium thickness [0.83-0.92 mm (0.33-0.036 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: Installing Pinion Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Measure the backlash between the side gears and pinions.
Standard value : 0.025-0.150 mm (0.001-0.006 in.)

0.025-0.0150 mm (0.001-0.006 in.)

Fig 3: Measuring Backlash Between Side Gears & Pinions
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.
CAUTION:
1. Do not reuse the lock pin.
2. The lock pin head must not protrude more than 3 mm (0.0118 in.) gear in the differential case.
Fig 4: Installing Lock Pin
Courtesy of KIA MOTORS AMERICA, INC.
Install the tapered roller bearing 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 Inner Race
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: BM stud locking No.2471

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

Fig 6: Identifying Differential Drive Gear Mounting Bolt Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.