Differentials - Front: Diagnosis Kia Sorento I

INSPECTION BEFORE DISASSEMBLY

Mount the differential carrier on the special tool (09517-43401).

Scheme 1

Scheme 2

1. Fix the drive gear so it cannot move and measure the final drive gear backlash with a dial indicator. NOTE: Measure at four points or more on the circumference of the drive gear. Standard value: 0.09-0.11 mm (0.0035-0.0043 in.)
2. If the backlash is beyond the standard value, adjust it using the side bearing spacer.

Note. After adjustment, inspect the contact of the final drive gear.

INSPECTION

1. Check the companion flange for wear or damage.
2. Check the bearings for wear or discoloration.
3. Check the gear carrier for cracks.
4. Check the drive pinion and drive gear for wear or cracks.
5. Check the side gears, pinion gears and pinion shaft for wear or damage.
6. Check the side gear spline for wear or damage.
7. Check the length of the distance piece.

Standard length

54.80-58.09 mm (2.16-2.21 in.)

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Scheme 28

1. PRESS-FITTING OIL SEAL
2. DRIVE PINION OUTER BEARING OUTER RACE INSTALLATION CAUTION: When press-fitting the outer race, do not incline it.
3. DRIVE PINION INNER BEARING OUTER RACE INSTALLATION CAUTION: When press-fitting the outer race, do not incline it.
4. ADJUSTMENT OF PINION HEIGHT Adjust the drive pinion height by using the following procedure. For assembly of pinion, use drive pinion model (0K993 270 A01), pinion height adjustment gauge body (0K993 270 A09) and gauge block (height 28 mm (1.102 in)). Assemble spacer and inner bearing inner race to pinion model and fix it with O-ring. NOTE: Use spacer disassembled. Install pinion model assembly to carrier. Assemble outer bearing, companion flange washer, and lock nut. NOTE: Use washer and lock nut disassembled. Tighten lock nut. NOTE: Tighten to the extent the companion flange can be screwed by hand. Put pinion height adjusting gauge body at right angle and adjust it to 0. Put pinion height adjusting gauge body and gauge block to the upper side of pinion model. Dial gauge needle should be placed at the lowest part of side bearing. Measure minimum (lowest) positions of both sides (LH, RH). Add both values and divide it by 2. If the value of the above step 10 is not within specification, use new spacer adding the values to current spacer. Standard clearance: -0.025 to 0.025 mm (-0.001 to 0.001 in)
5. ADJUSTMENT OF DRIVE PINION PRELOAD. Install spacer. Push inner bearing in using SST. NOTE: Keep pressuring until a sudden increase of power is necessary. Place the spacer for adjusting pinion height, ensuring exact direction of installation. Install distance piece. Push outer bearing in using SST. Install drive pinion assembly. Install companion flange and tighten lock nut. Tightening torque: 127-284 N.m (13-29 kg. m, 94-210 lb. ft) NOTE: Do not install oil seal. Turn companion flange by hand so that bearing is put at the right place. Measure preload of drive pinion. If the result is not within specification, use new distance piece and measure again. Preload: 127-176 N.m (13-18 kg. cm, 94-130 lb. ft) Remove the lock nut and then install the oil seal. Install the companion flange and tighten lock nut. Tightening torque: 127-284 N.m (13-29 kg. m, 94-210 lb. ft)
6. ADJUSTMENT OF DIFFERENTIAL GEAR BACKLASH Adjust the differential gear backlash according to the following procedures: Assemble the side gears, side gear spacers, pinion gears, and pinion washers into the differential case. Temporarily install the pinion shaft. NOTE: Do not install the lock pin yet. Insert a wedge in the side gear and measure the differential gear backlash with a dial indicator on the pinion gear. NOTE: Measure both pinion gears separately. Standard value: 0-0.1 mm (0-0.0039 in.) Limit: 0.2 mm (0.008 in.) If the differential gear backlash exceeds the limit, adjust the backlash by selecting thicker side gear thrust spacers. Measure the differential gear backlash once again, and confirm that it is within the limit. NOTE: After adjustment, check that the backlash is within the limit and the differential gear rotates smoothly. When adjustment is impossible, replace the side gear and the pinion gear as a set.
7. INSTALLATION OF THE LOCK PIN Align the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin. Fix the lock pin in place by staking two points around the lock pin hole with a punch.
8. INSTALLATION OF THE DRIVE GEAR Clean the drive gear attaching bolts. Remove the adhesive on the threaded holes of the drive gear using a tap (M10 x 1.25), and then clean the threaded holes with compressed air. Apply the specified adhesive to the threaded holes of the drive gear. Specified adhesive: LOCTITE #262 or equivalent Install the drive gear in the differential case with the matchmarks properly aligned. Tighten the bolts to the specified torque in a diagonal sequence. see scheme 28
9. PRESS-FIT THE SIDE BEARING INNER RACE
10. ATTACH ACTUATOR AT DIFFERENTIAL CASE CAUTION: Take notice of actuator direction.
11. ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH Adjust the final drive gear backlash according to the following procedures: Install side bearing spacers which are thinner than those removed, to the side bearing outer races, and then mount the differential case assembly into the gear carrier. NOTE: Select side bearing spacers with the same thickness for both the drive pinion side and the drive gear side. Push the differential case to one side, and measure the clearance between the gear carrier and the side bearing with a feeler gauge. Select two pairs of spacers, which correspond to the value calculated according to the expression in the illustration. Install one pair each to the drive pinion side and the drive gear side. Install the side bearing spacers and differential case assembly, as shown in the illustration, to the gear carrier. Tap the side bearing spacers with a brass bar to fit them to the side bearing outer race. Align the matchmarks on the gear carrier and the bearing cap and tighten the bearing cap. With the drive pinion locked in place, measure the final drive gear backlash with a dial indicator on the drive gear. NOTE: Measure at four points or more on the circumference of the drive gear. Standard value: 0.09-0.11 mm (0.0035-0.0043 in.) Change the side bearing spacers as illustrated and then adjust the final drive gear backlash between the drive gear and the drive pinion. NOTE: When increasing the number of side bearing spacers, use the same number for each side and as few as possible. Check the drive gear and drive pinion for tooth contact. If poor contact is evident, adjust again. Measure the drive gear runout at the shoulder on the reverse side of the drive gear. Limit: 0.05 mm (0.002 in.) If the drive gear runout exceeds the limit, reinstall by changing the position of the drive gear and differential case, and remeasure.

Scheme 29

1. Check the side gears, pinions, pinion thrust washers, and cross shaft for wear or damage. If there is excessive wear, cracks, nicks, grooves or galling, replace the parts.
2. Inspect the carbon surfaces. After cleaning with a solvent, the carbon surface should appear like a course weave fabric with flat spots on the peaks of the weave. If the surface is smooth, either from wear or from the weave filled with debris, replaces the entire disc pack.
3. Measure the thickness of the carbon friction discs. If any of the double sided discs are less than 2.56 mm (0.101 in.) or the single sided disc is less than 2.15 mm (0.085 in.), replace the entire disc pack.
4. Inspect the splined friction discs. If they have grooves or a mirror like finishing, replace the entire disc pack. Small scratches on a buff like finish are okay.

Scheme 30

1. Apply axle lubricant to all sliding surfaces. Be especially careful to coat the mating surfaces of the friction discs.
2. Starting with a double sided eared disc next to the side gear, stack four eared discs and three splined discs on to the spline of the side gear. A splined disc goes in between each eared disc with the last eared disc being single sided and the carbon surface facing the side gear. Use a heavy bearing grease in the ear guides to hold them in place during assembly.
3. Select a shim 0.76 mm (0.030 in.) thick and place on the hub side of the disc pack subassembly.
4. Lubricate and assemble the other side gears as above.
5. Install the flange end side gear subassembly and shim in the flange end of the differential case.
6. Position pinion gears and thrust washers on the side gears and install the cross shaft through the case and pinions.
7. Install a dial indicator on the case so that the indicator tip rests against a pinion tooth face.
8. Compress the clutch pack with a large screwdriver or pry bar as shown in illustration. Rotate the pinion gear back and forth to obtain backlash. Tooth backlash should be 0 to 0.10 mm (0 to 0.004 in.). If required, change the 0.76 mm (0.30 in.) Shim to obtain the proper backlash.
9. Remove the side gear subassembly and repeat the tooth backlash procedure for the other gear pack on the opposite side of the case.
10. Remove the cross shaft, pinions and thrust washers and reinstall the first side gear subassembly and shim in the flange end of the case.
11. Install a pinion and thrust washer through each window so that the gear teeth mesh and so that the pinions are in line with each other. Rotate one side gear so the pinions and thrust washers rotate at a position where they line up with the cross shaft holes in the case.
12. Install the pinion shaft, lock screw and lock washer. Tighten the lock screw to 30-40 Nm (3.1-4.1 kg. m, 22-29 lb. ft) torque.