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Repair Procedures (F21): Reassembly

WARNING: This page is about a different car, the 2011 Hyundai Veracruz. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  1. Clean all parts except the taper roller bearings. Be careful about the direction of seals.
  2. Oil bearings with hypoid gear oil API GL5.
  3. Smear involute splines all covering with high pressure grease "Klueber microlube GNY202".
  4. Measuring temperature: 20°±5°C.
  5. O-ring has to be dipped into hypoid gear oil API GL5. Allow excess oil to drain.
  6. Contact surface of the transfer housing to be coated with "SEALANT 732" or equivalent (silicon type sealing agent) prior to mounting. Coating thickness: 0.1 mm MIN. Prior to coating, mating surfaces must be clean and free from oil and grease.
  7. Transfer oil specification: Hypoid gear oil "API GL5, SAE 75W/90 SHELL SPIRAX X EQUIVALENT". Filled up to lower filler plug thread level (Approx. 0.8 L)
  8. The hypoid gear set must be managed as a pair. Whenever installing or replacing a hypoid gear shaft assembly (47308-24000/24010) or a pinion shaft (47311-39300/39310). Make sure to install or replace as a pair.
  9. In reassembling, refer to the two figures below.
    Fig 1: Checking Mating Surface
    G06861575Courtesy of HYUNDAI MOTOR CO.
  1. Install the transfer drive gear with the taper roller bearings (47366-39000 and 47465-39000) into transfer housing.
  2. Applying the preload (100 to 200 N) to bearings, measure the dimension J.
  3. Measure the dimension H on transfer cover (47314-24000).
  4. Select the spacer thickness from the table below. Thickness S4= H-J+K. (K: Bearing preload = 0.07 to 0.11 mm.) Corresponding preload torque (measured without seals): 120 to 180 Ncm.
    SPACER SPECIFICATION

    Part number Spacer thickness (mm)
    47383-39152 1.520-1.539
    47383-39154 1.540-1.559
    47383-39156 1.560-1.579
    47383-39158 1.580-1.599
    47383-39160 1.600-1.619
    47383-39162 1.620-1.639
    47383-39164 1.640-1.659
    47383-39166 1.660-1.679
    47383-39168 1.680-1.699
    47383-39170 1.700-1.719
    47383-39172 1.720-1.739
    47383-39174 1.740-1.759
    47383-39176 1.760-1.779
    47383-39178 1.780-1.779
    47383-39180 1.800-1.819
    47383-39182 1.820-1.839
    47383-39185 1.85-1.88
    47383-39189 1.89-1.92
    47383-39193 1.93-1.96
    47383-39197 1.97-2.00
    47383-39201 2.01-2.04
    47383-39205 2.05-2.08
    47383-39209 2.09-2.12
    47383-39213 2.13-2.16
    47383-39217 2.17-2.20
    47383-39221 2.21-2.24
    47383-39225 2.25-2.28
    47383-39229 2.29-2.32
    47383-39233 2.33-2.36
  5. Reassemble the selected spacer above.
  6. Measure the dimension U and V.

    U.... Finished dimension of transfer housing. 

    V.... Distance from back of the hypoid gear to bearing measured under 100 to 200 N preload. 

  7. Select the spacer thickness from the table below. Thickness S2=U-(V + mounting distance 52.0 mm).
    SPACER SPECIFICATION

    Part number Spacer thickness (mm)
    47384-39130 1.300-1.319
    47384-39134 1.340-1.359
    47384-39138 1.380-1.399
    47384-39142 1.420-1.439
    47384-39146 1.460-1.479
    47384-39148 1.480-1.499
    47384-39150 1.500-1.519
    47384-39152 1.520-1.539
    47384-39154 1.540-1.559
    47384-39156 1.560-1.579
    47384-39158 1.580-1.599
    47384-39160 1.600-1.619
    47384-39162 1.620-1.639
    47384-39164 1.640-1.659
    47384-39166 1.660-1.679
    47384-39168 1.680-1.699
    47384-39170 1.700-1.719
    47384-39174 1.740-1.759
    47384-39178 1.780-1.799
    47384-39182 1.820-1.839
    47384-39186 1.860-1.879
    47384-39190 1.900-1.919
    47384-39194 1.940-1.959
    47384-39198 1.980-1.999
    47384-39200 2.000-2.019
    47384-39202 2.020-2.039
    47384-39204 2.040-2.059
    47384-39206 2.060-2.079
    47384-39208 2.080-2.099
    47384-39210 2.100-2.119
  8. Install the spacer selected above, the taper roller bearings and the hypoid gear shaft assembly (47308-24000/24010). And preload the assembly without the spacer (Hypoid gear shaft assembly-Transfer cover side) with 100 to 200 N.
  9. Measure the dimension L after 10 rotations.
  10. Measure the dimension M on transfer cover (47314-24000).
  11. Select the spacer thickness from the table below. Thickness S3=M-L+(0.09 to 0.12 mm) preload.
    SPACER SPECIFICATION

    Part number Spacer thickness (mm)
    47388-24130 1.300-1.319
    47388-24132 1.320-1.339
    47388-24134 1.340-1.359
    47388-24136 1.360-1.379
    47388-24138 1.380-1.399
    47388-24140 1.400-1.419
    47388-24142 1.420-1.439
    47388-24144 1.440-1.459
    47388-24146 1.460-1.479
    47388-24148 1.480-1.499
    47388-24150 1.500-1.519
    47388-24152 1.520-1.539
    47388-24154 1.540-1.559
    47388-24156 1.560-1.579
    47388-24158 1.580-1.599
    47388-24160 1.600-1.619
    47388-24162 1.620-1.639
    47388-24164 1.640-1.659
    47388-24166 1.660-1.679
    47388-24168 1.680-1.699
    47388-24170 1.700-1.719
    47388-24172 1.720-1.739
    47388-24174 1.740-1.759
    47388-24176 1.760-1.779
    47388-24178 1.780-2.799
    47388-24180 1.800-2.819
    47388-24182 1.820-2.839
    47388-24184 1.840-2.859
    47388-24186 1.860-2.879
    47388-24250 2.50-2.53
  12. Install the spacer selected above.
  13. Install the taper roller bearing outer races to the transfer housing and cover.
  14. Install a new oil seal (A) in the transfer housing.
    Fig 2: Identifying Oil Seal
    G06861576Courtesy of HYUNDAI MOTOR CO.
  15. Install the transfer drive gear shaft assembly (A) and the hypoid gear assembly (B) in the transfer housing.
    Fig 3: Identifying Transfer Drive Gear Shaft Assembly
    G06861577Courtesy of HYUNDAI MOTOR CO.
  16. Measure the dimension F.

    F.... Assembled dimension of pinion assembly. 

    G.... Finished dimension of transfer housing (= 88.0 mm). 

    E.... Mounting distance (= 69.500 ± deviation). 

  17. Select the spacer thickness from the table below. Thickness S1=E+F-G
    NOTE: If it is not possible to reach the exact mounting distance, select the next thinner spacer S1.
    SPACER SPECIFICATION

    Part number Spacer thickness (mm)
    47386-39125 1.25-1.28
    47386-39129 1.29-1.32
    47386-39133 1.33-1.36
    47386-39137 1.37-1.40
    47386-39141 1.41-1.44
    47386-39145 1.45-1.48
    47386-39149 1.49-1.52
    47386-39153 1.53-1.56
    47386-39157 1.57-1.60
    47386-39161 1.61-1.64
    47386-39165 1.65-1.68
    47386-39169 1.69-1.72
    47386-39172 1.720-1.739
    47386-39174 1.740-1.759
    47386-39176 1.760-1.779
    47386-39178 1.780-1.799
    47386-39180 1.800-1.819
    47386-39182 1.820-1.839
    47386-39184 1.840-1.859
    47386-39186 1.860-1.879
    47386-39188 1.880-1.899
    47386-39190 1.900-1.919
    47386-39192 1.920-1.939
    47386-39194 1.940-1.959
    47386-39196 1.960-1.979
    47386-39198 1.980-1.999
    47386-39200 2.000-2.019
    47386-39202 2.020-2.039
    47386-39204 2.040-2.059
    47386-39233 2.33-2.36
  18. Install the pinion assembly with the selected spacer above and measure the circumference backlash on pinion.

    (Measuring diameter, backlash and permissible deviations for measurement on pinion, see table below).

    If the result is out of permissible range, change the spacer thickness S2, then start again with the step  8 ~  12).

    Tips For Spacer Adjustment For Hypoid Gear Backlash And Contact Pattern 

    PROBLEM SYMPTOMS

    Item Symptom Remedy
    Backlash When more than the standard value (0.16 ~ 0.21 mm) Adjust backlash by installing the spacer S1 using a thinner one and gradually installing a thicker one.
    When less than the standard value (0.16 ~ 0.21 mm) Adjust backlash by installing the spacer S1 using a thicker one and gradually installing a thinner one.
    PROBLEM SYMPTOMS

    Item Symptom Remedy
    Hypoid gear tooth contact pattern
    G06861578Courtesy of HYUNDAI MOTOR CO.
    • Normal state
    • Standard tooth pattern
      • Both drive and coast surfaces are in center in lateral direction and slightly incline to TOE side in vertical direction
    • If the pattern deviates from the standard, adjust it by following procedure
    G06861579Courtesy of HYUNDAI MOTOR CO.
    • Abnormal state
    • The drive surface inclines to TOE and TOP and the coast surface inclines to HEEL and TOP
    The tooth contact pattern can be moved to the arrow direction by installing the spacer S2 using a thinner one and gradually installing a thicker one.
  19. Remove the pinion assembly. With the spacer S3 and transfer cover mounted, combined preload torque for the hypoid gear shaft assembly and transfer gear (measured on transfer gear) should be 2.7 to 3.8 N.m. The spacer S3 has to be changed, if the preload torque is not within the permissible range.
  20. Tighten the pinion assembly mounting bolts (B-7EA) to install the pinion assembly (A).

    Tightening torque: 

    37 ~ 40 N.m (3.7 ~ 4.0 kgf.m, 14.5 ~ 21.7 lb-ft)

    NOTE:
    1. Before installing the pinion assembly, check the pinion O-ring and apply the oil to the O-ring.
    2. To make the installation of the pinion to the transfer easier, tap the pinion using a plastic hammer after aligning the bolt holes.
    Fig 4: Identifying Pinion Assembly Mounting Bolts
    G06861580Courtesy of HYUNDAI MOTOR CO.
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