Kia Sportage: Differential Carrier Assembly / Rear Differential Carrier / Repair procedures

Kia Sportage QL (2015-2019) Service Manual / Driveshaft and axle / Differential Carrier Assembly / Rear Differential Carrier / Repair procedures

Removal
1.
Remove wheel nuts, wheel and tire (A) from hub.
Tightening torque:
107.9 - 127.5 N·m (11.0 - 13.0 kgf·m, 79.6 - 94.0 lb·ft)

  
Be careful not to damage the hub bolts when removing the wheel & tire.
2.
Loosen the drain plug (A) and pull out the differential gear oil.
Tightening torque:
49.0 - 68.6N.m (5.0 - 7.0kgf.m, 36.1 - 50.6lb-ft)

3.
Remove the rear driveshaft.
(Refer to Rear Driveshaft Assembly - "Rear DriveShaft")
4.
Remove the propeller shaft.
(Refer to Propeller Shaft Assembly - "Propeller Shaft")
5.
Disconnect the connector from the coupling.

6.
Loosen the differential mounting bolts (A) and then remove the rear differential assembly.

7.
Loosen the bolts and then remove the coupling (A) and differential carrier (B).
Tightening torque :
56.9 - 64.7 N·m (5.8 - 6.6 kgf·m, 42.0 - 47.7 lb·ft)

8.
Loosen the bolts and then remove the differential carrier bracket.

9.
Install in the reverse order of removal.
10.
Check the wheel alignment.
(Refer to Suspension System - "Alignment")
Disassembly
Differential case disassembly
1.
Using the SST (09530-3T300), hold the differential assembly safely and then loosen the pillar plug (A).

2.
Loosen the cover bolts and then remove the cover.

3.
Loosen the bolts and then remove the bearing cap (A).

  
When removing it, make a match mark to the bearing cap and bolts in order to distinguish the left and right side.
4.
Remove the differential case assembly.

  
Mark the left and right side bearing race as below when removing the differential assembly to distinguish the sides.
5.
Using the screwdriver, remove the left and right side oil seal (A).

6.
Using the SST (09501-C9200) and the pully remove the front and rear bearing.

7.
Loosen the seal bolts and then remove the gear carrier (A) and ring gear (B).

  
Piant match marks on the gear carrier and the ring gear.
Pinion drive gear assembly
1.
Using the SST, remove the pinion lock nut.

2.
Using the press, separate the pinion drive gear assembly.

3.
Remove the pinion oil seal (A) and the pinion front bearing (B).

4.
Using a hammer and chisel, remove the pinion bearing outer race.
5.
Remove the pinion bearing spacer (A).

6.
Using the SST (09530-2W200), press the pinion drive gear and then remove the pinion rear bearing.

7.
Remove the pinion frontbearing (A), Inner bearing adjustment shim (B) in the order.

Inspection
1.
After clearing, check for damage parts or abrasion. Follow the below method, if any are noticed.
Item
Identify
Gear set (drive pinion gear & drive gear)
The gear set must be replaced with a new one if the gear tooth is damaged (crack/pits/dents).
Bearing
The bearing must be replaced with a new one if the bearing roller or race is damaged (crack/pits/dents).
Oil seal
The oil seal must be replaced with a new one if disassembled.
Differential carrier
The carrier must be replaced with a new one if the inside of the carrier bearing is damaged (crack/pits/dents) or a crack is found inside/ouside.
Companion flange
The pinion oil seal must be replaced with a new one if the contact surface is damaged (crack/pits/dents).
Open type
Diff gear set
(Diff side gear & diff pinion gear)
The gear set must be replaced with a new one if the gear tooth or tooth surface is damaged (crack/pits/dents).
Diff washer
(Diff side gear washer & diff pinion gear washer)
The wahser must be replaced with a new one if the washer surface is damaged (crack/pits/dents).

Reassembly
  
The already adopted seam for controlling the inner bearing on the front differential assembly is used. (Use the same thickness controlling seam in case of destruction)
The rear differential assembly shall be replaced with new one when the differential carrier or differential case assembly is failed.The noise or vibration can be made due to the no matching of current inner bearing and gear control seam when the carrier or differential case assembly is exchanged as a unit.
[Differential carreir]
1.
Using the SST, install the pinion front bearing outer race.

2.
Using the SST, install the pinion rear bearing outer race.

3.
Install the pinion front bearing (A), Inner bearing adjustment shim (B) in the order.

  
The already adopted seam for controlling the inner bearing on the front differential assembly is used. (Use the same thickness controlling seam in case of destruction)
The rear differential assembly shall be replaced with new one when the differential carrier or differential case assembly is failed.The noise or vibration can be made due to the no matching of current inner bearing and gear control seam when the carrier or differential case assembly is exchanged as a unit.
4.
Using the round pipe, press in the pinion rear bearing (B).

5.
Install the pinion bearing spacer (A).

6.
Install the pinion front bearing and then install the pinion oil seal.

7.
Using the press, install the pinion drive gear to the differential carrier.

8.
Using SST, install the side oil seal.

9.
Using SST, install the pinion lock nut.

10.
Measures the pinion freeroad.
Standard :
0.9 - 1.8 N·m (9.2 - 18.3 kgf·m, 0.7 - 1.3 lb·ft)

  
Maintain the constant speed rotation (60rpm).
  
If the measured value is exceeded the standard value, should be exchanged the spacer (A) with a new one.
[Differential case assembly]
1.
Install the gear carrier and ring gear.

  
Tighten the seal bolts in a crisscross pattern.
2.
Using the SST (09543-02100) and press, install the side bearing.

3.
Install the differential case assembly to the differential carrier.

  
Install the left and right side spacers to the differential carrirer.
Install the left and right side bearing outer races to the differential case.
Hold the left and right side bearing outer races with both hands and install the differential case assembly to the differential carrier.
Use a new bearing and outer races when reinstalling.
4.
Install the bearing cap (A).
Tightening torque :
44.1 - 53.9 N·m (5.5 - 6.5 kgf·m, 32.5 - 39.8 lb·ft)

5.
Measures the gear backrash.
Standard :
0.07 - 0.15 mm ( 0.003 - 0.006 inch)
  
The thickness of both spacers shall be adjusted by disassembling again when the backlash is bigger or smaller than the Standard.
6.
Measures the total freeroad.
Total preload :
Pinion bearing preload (9.2 - 18.3 kgf·m) + (2.5 - 8.5 kgf·m)

  
Maintain the constant speed rotation (60rpm).
  
If the measured value is exceeded the standard value, should be exchanged the spacer (A) with a new one.
And then should be Rework.

7.
Apply the red lead paint to the ring gear teeth and then rotate the gear in order to check the tooth contact pattern.

Tooth contact
Sontact state
Solution
Standard contact



1. Wheel contact

Increase the thickness of the pinion height adjusting shim, and position the drive pinion closer to the center of the drive gear.
Also, for backlash adjustment, reposition the drive gear further from the drive pinion.

2. Face contact

3. Toe contact

Decrease the thickness of the pinion height adjusting shim, and position the drive pinion further from the center of the drive gear.
Also, for backlash adjustment, reposition the drive gear closer to the drive pinion.

4. Flank contact


  
1)
Tooth contact pattern is a method for judging the result of the adjustmentof drive pinion height and final drive gear backlash. The adjustment of drivepinion height and final drive gear backlash should be repeated until the toothcontact patterns are similar to the standard tooth contact pattern.
2)
When you cannot obtain a correct pattern, the drive gear and drive pinionhave exceeded their limits. Both gears should be replaced as a set.
8.
Coat sealant (A) on the rear cover surface.
Sealant : LT#5060 Equivalent

  
Remove the remaining sealant before coating.
Evenly coat the sealant 2-3 mm thick along the rear cover surface.
9.
Install the differential rear cover (A).
Tightening torque :
78.5 - 88.3 N·m (8.0 - 9.0 kgf·m, 57.9 - 65.1 lb·ft)

10.
Install the drain plug (A).
Tightening torque :
49.0 - 68.6 N·m (5.0 - 7.0 kgf·m, 36.1 - 50.6 lb·ft)

11.
Inject the gear oil.
Specified lubricant :
MS517-15GT 75W/90(GL-5)
(SHELL HD AXLE OIL 75W/90 or SK HK G-5 75W/90 equivalent)
Oil quantity(L) : 0.58 ± 0.05

12.
Install the pillar plug.
Components and components location
Components Location 1. Rear driveshaft LH 2. Coupling assembly 3. Rear differential carrier assembly 4. Rear driveshaft RH 5. Propeller shaft ...

Driveshaft Assembly
...

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