Kia Sportage: Rear Differential Carrier: Repair procedures - Differential Carrier Assembly - Driveshaft and axle - Kia Sportage SL Service & Repair ManualKia Sportage: Rear Differential Carrier: Repair procedures

Third generation SL (2010Ц2016) / Kia Sportage SL Service & Repair Manual / Driveshaft and axle / Differential Carrier Assembly / Rear Differential Carrier: Repair procedures

Replacement
1.
Drain the differential gear oil.
   
Filler plug (A) & Drain plug (B) tightening torque.

Tightening torque
Filler plug (A): 39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43 lb-ft)
Drain plug (B): 49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)

2.
Remove the rear drive shaft. (Refer to rear drive shaft.)
3.
Remove the propeller shaft. (Refer to propeller shaft.)
4.
Disconnect the coupling control connector wire clip (A).

5.
Disconnect the coupling control connector (A).

6.
Support the differential assembly (A) with the jack.

Tightening torque :
68.6 ~ 88.3N.m (7.0 ~ 9.0kgf.m , 50.6 ~ 65.1Ib-ft)

7.
After loosen the bolt and then remove the differential carrier (B) from the coupling(A).

8.
Install in the reverse order of removal.
9.
Add diff gear oil fluid to differential carrier.
   
Filler plug (A) & Drain plug (B) tightening torque.

Tightening torque
Filler plug (A): 39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43 lb-ft)
Drain plug (B): 49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)

Inspection
Install the differential carrier assembly (A) with the special tools (09517-43401 & 09517-43500).Then carry out the following inspection.

1.
Check the final drive gear backlash by the following procedure.
(1)
Place the drive pinion and move the drive gear to check backlash is within the standard range.
   
Measure at 4 points on the gear periphery.

Standard value :
0.10 ~ 0.15mm (0.0039 ~ 0.0059in.)

2.
Check the drive gear back-face lash by the following procedure.
(1)
Place a dial gauge on the back-face of the drive gear and measure the runout.

Limit : 0.05 mm (0.002 in)

(2)
If the runout is beyond the limit, check that there are no foreign substances between the drive gear and differential case and, that the bolts fixing the drive gear are not loose.
3.
Check the differential gear backlash by the following procedure.
(1)
Fix the side gear with a wedge so it cannot move and measure the differential gear backlash with a dial indicator on the pinion gear.

Standard value :
0 ~ 0.05 mm (0 ~ 0.002 in)

   
Take the measurements at two places on the pinion gear.

(2)
If the backlash exceeds the limit, adjust using side bearing spacers.
   
If adjustment is impossible, replace the side gear and pinion gear as a set.
4.
Check the tooth contact of the final drive gear by the following procedure.
(1)
Apply the same amount of machine blue slightly to both surfaces of the drive gear teeth.

(2)
Insert a brass rod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear so that some torque (approximately 25~30Nm) is applied to the drive pinion.

   
If the drive gear is rotated too much, the tooth contact pattern will become unclear and difficult to check.
(3)
Check the tooth contact pattern.
Tooth contact
Contact state
Solution
Standard contact



1. Heal 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


   
Х
Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear backlash. The adjustment of drive pinion height and final drive gear backlash should be repeated until the tooth contact patterns are similar to the standard tooth contact pattern.
Х
When you cannot obtain a correct pattern, the drive gear and drive pinion have exceeded their limits. Both gears should be replaced as a set.
5.
Check the oil leaks and the lip part for chew or wear.
6.
Check the bearings for wear or discoloration.
7.
Check the gear carrier for cracks.
8.
Check the drive pinion and drive gear for wear or cracks.
9.
Check the side gears, pinion gears and pinion shaft for wear or damage.
10.
Check the side gear spline for wear or damage.
Rear Differential Carrier: Components and Components Location
Component 1. Drive pinion nut 2. Oil seal3. O-ring4. Oil seal5. Front bearing6. Spacer7. Rear bearing8. Inner shim9. Drive pinion gear10. Differential carrier11. Bearing cap12. Bearing cap bolt1 ...

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