Repair procedures: Reassembly

Install the spacer on the back of the side gear and then install the pinion gear (A) in the differential case.

Fig 1: Installing Pinion Gear In Differential Case
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
- When installing a new side gear, use a spacer of medium thickness [0.83-0.92 mm (0.33-0.036 in.)].
- Do not reuse the lock pin.
- 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 (B) by turning them.
Insert the pinion shaft (A).

Fig 2: Inserting Pinion Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Measure the backlash between the side gears and pinions.
Standard value :
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 (C) lock pin hole with the case lock pin hole and insert the lock pin (B).
CAUTION:
- Do not reuse the lock pin.
- The lock pin head must not protrude more than 3 mm (0.0118 in.).
  
  Fig 3: Identifying Pinion Shaft Lock Pin Hole And 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 4: Pressing Bearing
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 5: Identifying Entire Threads Of Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.