Hyundai Kona: Differential Carrier Assembly / Rear Differential Carrier Repair procedures

Removal
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from rear hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)
  
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).

3.
Remove the rear driveshaft.
(Refer to Rear Driveshaft Assembly - "Rear DriveShaft")
4.
Remove the propeller shaft.
(Refer to Propeller Shaft Assembly - "Propeller Shaft")
5.
Disconnect the pressure sensor connector (A).

6.
Disconnect the oil hydraulic Motor connector (A).

7.
Support the differential assembly with the jack.
8.
After loosening the differential mounting bolts and remove the differential assembly (A).

9.
Remove the differential carrier (B) from the coupling (A).

10.
Remove the differential carrier bracket (A).

Disassembly
[Differential Case Assembly]
1.
Drain oil by removing the drain plug (A) before removing the rear differential carrier.

2.
Using the SST (09501-C9230), hold the differential assembly safely.

3.
Loosen the cover bolts and then remove the cover (A).

4.
Remove the gear carrier assembly (A).

5.
Using the SST (09501-C9200), remove the front / rear bearing.

  
Do not use the bearing again.
6.
Loosen the seal bolts and then remove the gear carrier (A) and ring gear (B).

[Pinion Drive Gear Assembly]
1.
Using the SST (09501-C9230), remove the pinion gear lock nut (A).

2.
Using the press, remove the pinion drive gear (A).

3.
Remove the spacer (A) from the pinion drive gear assembly.

4.
Remove the oil seal (A).

5.
Using the SST (09501-C9140), remove the upper / lower race.

  
Using the SST (09501-C9140), install in the hole.

6.
Using the press and SST (09501-C9120, 09452-2E000), remove the pinion bearing from the pinion drive gear.

  
Do not use the bearing again.
7.
Remove the bearing adjust (A) from the pinion drive gear.

8.
Using the (-) driver, remove the front / rear bearing race and spacer.

  
Put the (-) driver in the hole part, remove the front / rear bearing race and spacer.

9.
Remove the differential carrier side oil seal (A).

Reassembly
  
The already adopted seam for controlling the inner bearing on the front differential assembly is used. (Use the same thickness controlling seam in case of destruction)
The rear differential assembly shall be replaced with new one when the differential carrier or differential case assembly is failed.
The noise or vibration can be made due to the no matching of current inner bearing and gear control seam when the carrier or differential case assembly is exchanged as a unit.
1.
Install the Inner bearing adjustment shim (A) to the pinion drive gear.

2.
Using the press and SST (09501-C9130), install the pinion bearing.

3.
Install the spacer (A) from the pinion drive gear assembly.

  
Be careful not to deflect the spacer (A) when mounting it.
Normal mounting
Abnormal mounting


4.
Using the SST (09501-C9150), install the upper outer race and bearing (A).

5.
Using the SST (09501-C9150), install the lower outer race and bearing (A).

6.
Install the upper bearing (A).

7.
Using the press, install the pinion drive gear assembly (A).

8.
Using the SST (09501-C9100, 09231-H1100), install the pinion oil seal.

9.
Using the SST (09501-C9230), install the pinion lock nut (A).

10.
Measures the pinion freeroad.
Pinion preload : (9.2 - 18.3 kgf.m)

  
Maintain the constant speed rotation (60rpm).

  
If the measured value is exceeded the standard value, should be exchanged the spacer (A) with a new one. And then should be Rework.

11.
Using the SST (09231-H1100, 09501-C9190), install the side oil seal.

12.
Install the side bearing race.

[Differential Case Assembly]
1.
Install the differential case (A) and ring gear (B).

2.
Using the SST (09501-C9210) and press, install the front / rear bearing.

3.
Install the differential case (A).

4.
Install the side cover.
Sealant : L5702

  
Remove the remaining sealant before coating.
Apply along the rear cover surface to the 2~3 mm of thickness evenly.
5.
Measures the differential rear backlash.
Differential gear backlash : 0.01 - 0.06 mm

6.
Measures the total preload.
Standard : Pinion freeroad +0.24 - 0.83 N.m (+2.5 - 8.5 kgf.cm, 0.18 - 0.62 lb-ft)
  
Maintain the constant speed rotation (60rpm).

7.
Install the drain plug (A).
Tightening torque :
49.0 - 68.6 N.m (5.0 - 7.0 kgf.m , 36.2 - 50.6 Ib-ft)

Inspection
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 wahser must be replaced with a new one if the washer surface is damaged (crack/pits/dents).

Installation
1.
Install the differential carrier bracket (A).

2.
Install the differential carrier (B) and the coupling (A).
Tightening torque :
56.9 - 64.7 N.m (5.8 - 6.6 kgf.m, 42.0- 47.7 lb-ft)

3.
Install the differential carrier and coupling assembly (A).
Tightening torque :
68.6 - 88.3 N.m (7.0 - 9.0 kgf.m , 50.6 - 65.1 Ib-ft)

4.
Add new oil through the filler plug hole (A).
Oil type :
Hypoid gear oil MS517-15 GT 75W/90 (GL-5)
(SHELL HD AXLE OIL 75W90), SK HK G-5 75W90 Equivalent)
Oil capacity (L) :
0.50 ± 0.05 L
Tightening torque :
39.2 - 58.8 N.m (4.0 - 6.0 kgf.m, 28.9- 43.4 lb-ft)

5.
Connect the oil hydraulic motor connector (A).

6.
Connect the pressure sensor connector (A).

7.
Install the propeller shaft.
(Refer to Propeller Shaft Assembly - "Propeller Shaft")
8.
Install the rear driveshaft.
(Refer to Rear Driveshaft Assembly - "Rear DriveShaft")
9.
Install the rear wheel and tire (A) from rear hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)
  
Be careful not to damage the hub bolts when installing the rear wheel and tire (A).

Rear Differential Carrier Components and components location
Components Location 1. Rear drive shaft (LH) 2. Coupling assembly 3. Rear differential carrier assembly 4. Rear drive shaft (RH) 5. Propeller shaft assembl ...

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