Differential Carrier Assembly Hyundai Santa Fe III

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1. Remove the rear wheel and tire (A) from rear hub. Tightening torque: 88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft) NOTE: Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
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»(/hyundai/santa-fe/iii-2012-2016/remont/differentials-drive-axles/#rear-driveshaft-assembly) .
4. Remove the propeller shaft. Refer to «PROPELLER SHAFT»(/hyundai/santa-fe/iii-2012-2016/remont/driveshaft-universal-joints/#propeller-shaft-assembly) .
5. Remove cover (B) as loosen screw (A-4ea).
6. Disconnect the pressure sensor connector (A) and oil hydraulic motor connector (B).
7. Remove rear differential assembly (B) as loosen mounting (A-4ea) after install jack Tightening torque: 49.0 ~ 68.6N.m (5.0 ~ 7.0kgf.m, 36.1 ~ 50.6lb-ft)
8. After loosen the bolt and then remove the differential carrier (B) from the coupling (A). Tightening torque: 56.9 ~ 64.7N.m (5.8 ~ 6.6kgf.m, 42.0~47.7lb-ft)
9. Install in the reverse order of removal.
10. Gear oil is injected. Specified lubricant: Hypoid gear oil API GL-5, SAE 75W/90 (SHELL SPIRAX X or equivalent) Oil quantity: Fill up to the bottom level of the filler plug hole (About 0.53L)
11. Check the rear alignment. Refer to «REAR ALIGNMENT»(/hyundai/santa-fe/iii-2012-2016/remont/suspension-rear/#rear-suspension-system-wheel-alignment) .

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1. Drain oil by removing the drain plug (A) and filler plug (B) before disassembling the rear differential carrier. NOTE: Use a new drain plug and pillar plug whenever installing.
2. Using the SST(09530-3T300), hold the differential assembly safely.
3. Remove the air breather plug (A).
4. Loosen the cover bolts (A-8EA) and then remove the cover (B).
5. Loosen the bolts (A-4EA) and then remove the bearing cap (B).
6. Remove the gear carrier assembly (A).
7. Mark the left and right side bearing race as below when removing the differential assembly to distinguish the sides.
8. Using the screwdriver, remove the left and right side oil seal (A). NOTE: Use a new oil seal whenever installing.

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1. Loosen the seal bolts and then remove the gear carrier (A) and ring gear (B). Information Paint match marks on the gear carrier and the ring gear.
2. Using the SST (09530-3T200) remove the front and rear bearing (A).
3. Mark the left and right side bearing as below when removing the bearing to distinguish the sides.

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1. Using the SST(09530-3T300), fix the differential carrier assembly.
2. Fix the SST (09530-2W300) on the lock nut.
3. Fix the flange fix (A) on the SST (095302W300).
4. Insert the SST (095302W400) to the hole of the hexagon and then remove the lock nut (A).
5. Using the screwdriver, remove the pinion oil seal (A).
6. Press the drive gear and remove the pinion front bearing (A).
7. Using a hammer and chisel, remove the pinion bearing outer race (A).
8. Using the SST (09527-4A000), press the pinion drive gear and then remove the pinion bearing spacer (A), the inner bearing (B), Inner bearing adjustment shims (C) in the order.

Pinion drive gear height adjustment

Adjust the height of the drive pinion in the following order.

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1. Below are the special tools to measure the pinion height
2. The special tool lock nut (A), pinion oil seal (B), pinion front bearing (C), inner bearing (D) and special tool support body (E) are mounted as follows. Tightening torque lock nut (A): 88.3~137.3Nm (9.0~14.0kgf.m, 65.1~101.3lb-ft)
3. Put the main body (A) on the Differential Case (B).
4. The bearing cap (B) is mounted on the main body (A). Tightening torque: 54.0~63.7Nm (5.5~6.5kgf.m, 39.8~47.0lb-ft)
5. Using the feeler gage, measure the gap between the main body (A) and bearing cap (B). And then select the inner bearing adjustment shim.
6. Install the selected inner bearing (A) adjustment shim. INNER BEARING ADJUSTMENT SHIM SPECIFICATION Part NO. Thickness inch 53040-3C138 1.38 0.054 53040-3C141 1.41 0.055 53040-3C144 1.44 0.057 53040-3C147 1.47 0.058 53040-3C150 1.50 0.059 53040-3C153 1.53 0.06 53040-3C156 1.56 0.061 53040-3C159 1.59 0.063 53040-3C162 1.62 0.064 53040-3C165 1.65 0.065 53040-3C168 1.68 0.066 53040-3C171 1.71 0.067 53040-3C174 1.74 0.068 53040-3C177 1.77 0.067

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1. Using the SST (09530-3T100), install the inner pinion bearing outer race (A).
2. Using the SST (09530-3T100), install the outer pinion bearing outer race.
3. Using the round pipe (A), press in the pinion rear bearing (B).
4. Install the pinion bearing spacer (B) on the pinion drive gear (A). NOTE: Must be use new spacer.
5. Using the round pipe (A), press the front bearing (B).
6. Using the SST (09530-3T600), install the pinion oil seal.
7. Using the SST(09530-3T300), install the pinion lock nut (A). Tightening torque: 186.33~441.3Nm (19.0~45.0kgf.m, 137.43~325.48lb-ft) NOTE: Must be use new lock nut.
8. tighten the lock nut. Standard (pinion bearing preload): 92.22~179.46Nm (9.2~18.3kgf.m, 66.54~132.36lb-ft) Information Maintain the constant speed rotation (60rpm).

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1. Using the SST (09453-3B200), install the front/rear bearing (A).
2. Install the gear carrier and ring gear. Tightening torque: 137.3~156.9Nm (14.0~16.0kgf.m, 101.3~115.7lb-ft) Information When tightening the seal bolt, please do it diagonal.
3. Install the left and right side bearing outer race (A) to the gear carrier.
4. Fix the left and right side bearing outer race (A) with both hands and install it on the differential case.
5. Insert the left and right adjustment spacer between the differential side bearing and carrier. And than install the bearing cap (A) with mark. Tightening torque: 53.9~63.7Nm (5.5~6.5kgf.m, 39.8~47.0lb-ft)
6. Adjust the differential shim and confirm the standard of the backlash. Standard : 0.10 ~ 0.15 mm (0.004~0.006 inch) Information Thickness of the differential shim needs to be adjusted if backlash is small. Reduce the thickness of the left side differential shim and enlarge the thickness of the right side differential shim as much as the reduced left side.
7. Adjust gear assembly run out backlash. Standard : 0~0.05mm(0~0.002inch)
8. Measures the freeload. Standard Pinion bearing preload: 0.25~0.84Nm (2.5 ~ 8.5 Kgf.cm, 0.18~0.62 lb-ft)
9. Coat sealant (A) on the rear cover surface. Sealant : MS 721-40 Information Remove the remaining sealant before coating. Evenly coat the sealant 2~3 mm thick along the rear cover surface.
10. Install the differential rear cover (A). Tightening torque: 39.2~49.0Nm (4.0 ~ 5.0 kgf.m, 28.9~36.2 lb-ft)
11. Install the drain plug (A) and pillar plug (B). Pillar plug: 39.2~58.8Nm (4.0 ~ 6.0 kgf.m, 28.9~43.4 lb-ft) Drain plug: 49.0~68.6Nm (5.0 ~ 7.0 kgf.m, 36.2~50.6 lb-ft)
12. Using the SST (09530-3T000), install the left and right side oil seal.
13. Reassemble the rear differential assembly to the vehicle and inject oil. Oil type : Hypoid gear oil, MS 517-15GT (SAE 75W/90, API GL-5, SHELL SPIRAX Oil capacity (L) : 0.53±0.05L

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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 washer must be replaced with a new one if the washer surface is damaged (crack/pits/dents). LSD type Limited slip differential assembly The limited slip differential assembly must be replaced with a new one if a crack is found outside.
2. Check the tooth contact pattern. Tooth contact Contact state Solution Standard contact 1. Heel 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 NOTE: 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. 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.

See also:
• REAR DRIVESHAFT
• PROPELLER SHAFT
• REAR ALIGNMENT