Differentials - Front: Other Kia Sorento I

GENERAL

Note. Axle shafts are referred to as drive shafts in this article. Axle (drive) shafts are what transfer driveline power from transaxles and differentials to the wheel hubs on independent suspension systems. Propeller shafts are referred to in this article as drive shafts. Propeller (drive) shafts are what transfer driveline power from transmissions and transfer cases to the differentials.

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1. Drain oil. CAUTION: When removing the drive shaft, be careful not to damage the differential carrier oil seal by interference of spline part.
2. Remove the drive shaft and the output shaft. See «AXLE SHAFTS»(ref-166047) . NOTE: Make match mark on the flange yoke and differential companion flange to avoid any mistake when installing them again.
3. Remove the front propeller shaft. See «PROPELLER SHAFT ASSEMBLY»(ref-169116-S06976154662004113000000) .
4. Remove the power steering tube mounting bracket. Tightening torque: 18-23 N.m (1.8-2.3 kg. m, 13-16 lb. ft)
5. Remove the differential mounting bracket.
6. Remove the front member.
7. Remove the differential mounting bolt.
8. Remove the differential carrier.

DRIVE GEAR RUNOUT

Check the back-face lash as follows

1. Place a dial gauge on the back-face of the drive gear and measure the runout. Limit: 0.05 mm (0.0020 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. If nothing is wrong in step 2 , adjust the drive gear depth and remeasure.

Note. If these adjustments cannot be corrected, replace the case or install a new drive gear/drive pinion as a set.

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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. NOTE: Take the measurements at two places (4 places for LSD) on the pinion gear. Standard value: 0-0.1 mm (0-0.0039 in.)
2. If the backlash exceeds the limit, adjust using side bearing spacers.

Note. If adjustment cannot be corrected, replace the side gear and pinion gears as a set.

FINAL DRIVE GEAR TOOTH CONTACT

Check the final drive gear tooth contact by performing the following steps

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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 25-30 kg-cm) is applied to the drive pinion. CAUTION: 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.

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.

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FUNCTION CHECK

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1. Air pressure gauge is attached in between air hoses that connect differential (actuator) with air pump motor assembly. Air pressure gauge adjustment screw shall be tightened until it stops. Make a blind stopper at air check side by using fuel hose etc.
2. Turn the ignition switch on and shift the transfer lever 2H --> 4H.
3. Check that the motor starts to revolve in 1 second and stops when air pressure gauge value is displayed within the specified value. Specified pressure: 37-57 kPa (5.4-8.2 lb/in 2 , 0.38-0.58 kgf/cm 2 ). CAUTION: Also check for air leak.
4. Check that if transfer lever is shifted to 2H then promptly Air pressure gauge value drops down.
5. Confirm that motor returns when air pressure adjustment screw has been loosened to lower the gauge pressure value after motor had started to revolve by shifting transfer lever to 4H. Also check that the motor stops after several seconds since it started to run.

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1. Detach air hose from air pump motor assembly and then attach air pressure gauge at air hose as in illustration. CAUTION: Take heed that there is potential for diaphragm breakage if pressure beyond 200 kPa (28 lb/in 2 , 2.0 kgf/cm 2 ) is applied. Do not use the air gun.
2. Attach compressor air hose to Air pressure gauge and then set to specified pressure by fastening adjustment screw. Check that actuator is operated to affect the axle lock.

Specified pressure

37 kPa (5.4 lb/in 2 , 0.38 kgf/cm 2 ).

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1. Attach air pressure gauge, voltmeter and battery to air pump motor, as in illustration. Air pressure gauge adjustment screw shall be tightened until it stops. Make a blind stopper at air check side by using fuel hose etc.
2. Confirm that motor runs when battery has been connected. Check that motor stops when returned to specified pressure. Specified pressure: 37-57 kPa (5.4-8.2 lb/in 2 , 0.38-0.58 kgf/cm 2 ). CAUTION: Also check for air leak.
3. Read voltmeter indication value so as to check if it is within specified range.

Voltage

about 0 V (when motor runs)

10-14 V (when motor stopped)

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1. REMOVAL OF THE DIFFERENTIAL CASE ASSEMBLY CAUTION: Remove the differential case assembly slowly and carefully. Be careful so that the side bearing outer race is not dropped. NOTE: Keep the right and left side bearings separate so that they are not mixed during reassembly.
2. REMOVAL OF THE SIDE BEARING INNER RACES Fit the nut on top of the differential case, and then use the special tool (09517-43001) to remove the side bearing inner race. NOTE: Attach the prongs of the special tool to the inner race of the side bearing through the notched section in the differential case.
3. REMOVAL OF DRIVE GEAR Make the matchmarks to the differential case and the drive gear. Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear.
4. REMOVAL OF LOCK PIN (FOR CONVENTIONAL DIFFERENTIAL)
5. REMOVAL OF SELF-LOCKING NUT
6. REMOVAL OF DRIVE PINION Make the matchmarks to the drive pinion and companion flange. CAUTION: Matchmarks should not be made to the contact surfaces of the companion flange and the propeller shaft. Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims.
7. REMOVAL OF DRIVE PINION INNER BEARING INNER RACE
8. REMOVAL OF OIL SEAL / DRIVE PINION OUTER BEARING INNER RACE / DRIVE PINION OUTER BEARING OUTER RACE
9. REMOVAL OF DRIVE PINION INNER BEARING OUTER RACE

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