Kia Sportage: Components and Components Location | Repair procedures

 Component

1. Drive pinion nut
2. Oil seal
3. O-ring
4. Oil seal
5. Front bearing
6. Spacer
7. Rear bearing
8. Inner shim
9. Drive pinion gear
10. Differential carrier
11. Bearing cap
12. Bearing cap bolt
13. Plate baffle
14. Carrier cover
15. Vent plug
16. Cover fix bolt
17. Dower pin
18. Filler gasket
19. Filler plug
20. Carrier sub assembly
21. Cover sub assembly
22. Drain plug gasket
23. Drain plug
24. Diff pinion washer
25. Diff pinion
26. Diff shaft
27. Diff gear
28. Diff gear washer
29. Lock pin
30. Diff case
31. Ring gear bolt
32. Diff bearing
33. Diff shim
34. Diff oil seal
35. F/driven gear

Repair procedures

Replacement

1. Drain the differential gear oil.

NOTE

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 ~ 9.0kgfm , 50.6 ~ 65.1lb-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.

NOTE

Filler ping (A) & Drain ping (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 & 09517-43 500).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.

NOTE

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.

• 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)

NOTE

Take the measurements at two places on the pinion gear.

2. If the backlash exceeds the limit, adjust using side bearing spacers.

NOTE

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.

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 then limits. Both gear s 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.

READ NEXT: