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

Replacement
1.
Drain the differential gear oil.
2.
Remove the rear drive shaft.
3.
Remove the propeller shaft.
4.
Disconnect the coupling control connector (A).

5.
Support the differential assembly (A) with the jack (B).

Tightening torque :
68.6 ~ 88.3N.m (7.0 ~ 9.0kgf.m , 50.6 ~ 65.1Ib-ft)

6.
After loosen the cover bolt and then remove the differential cover (A).

Tightening torque :
39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m , 28.9 ~ 36.2Ib-ft)

7.
Install in the reverse order of removal.
Disassembly
Rear differential carrier disassembly
1.
Drain oil by removing the drain plug (A) and pillar plug (B) before disassembling the rear differential carrier.

   
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).
   
Use a new oil seal whenever installing.

Gear carrier assembly disassembly
1.
Loosen the seal bolts and then remove the gear carrier (A) and ring gear (B).
   
Piant 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.

disassembly the pinion assembly
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 front bearing (B), Inner bearing adjustment shims (C) in the order.

Reassembly
Pinion drive gear height adjustment
Adjust the height of the drive pinion in the following order.
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 ~ 137.3 Nm (9.0 ~ 14.0 kgf.m, 65.1 ~ 101.3 lb-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 ~ 63.7 Nm (5.5 ~ 6.5 kgf.m, 39.8 ~ 47.0 lb-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
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

Rear differential carrier reassembly
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).
   
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), tighten the pinion lock nut (A).

Tightening torque :
186.33~441.3Nm (19.0~45.0kgf.m, 137.43~325.48 lb-ft)

8.
Measure the Preload.

Standard :
92.22 ~ 179.46Nm (9.2 ~ 18.3kgf.m, 66.54~132.36 lb-ft)

   
Maintain the constant speed rotation (60rpm).

   
If it is not in standard, follow above procedures again.
Re-use of spacer is not allowed in disassembling and reassembling when preload is over spec.
Gear carrier assembly reassembly
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 ~ 115.7 lb-ft)

   
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 baearing cap (A) with mark.

Tightening torque :
53.9 ~ 63.7 Nm (5.5 ~ 6.5 kgf.m, 39.8 ~ 47.0 lb-ft)

6.
Adjust the differential shim and confirm the standard of the backrash.

standard : 0.10 ~ 0.15 mm ( 0.004 ~ 0.006 inch)

   
Thickness of the differential shim needs to be adjusted if backrass 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 backrash.

Standard : 0 ~ 0.05mm(0 ~ 0.002inch)

8.
Measures the freeroad.

Standard : Pinion freeroad : 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

   
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 ~ 49.0 Nm (4.0 ~ 5.0 kgf.cm, 28.9 ~ 36.2 lb-ft)

11.
Install the drain plug (A) and pillar plug (B).

Pillar plug :
39.2 ~ 58.8 Nm (4.0 ~ 6.0 kgf.cm, 28.9 ~ 43.4 lb-ft)
Drain plug :
49.0 ~ 68.6 Nm (5.0 ~ 7.0 kgf.cm, 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 : Hyjpoid gear oil, MS 517-15GT (SAE 75W/90, API GL-5, SHELL SPIRAX
Oil capacity (L) : 1.4 ± 0.05L

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).
LSD type
limited slip differntial 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


   
1.
Tooth contact pattern is a method for judging the result of the adjustmentof drive pinion height and final drive gear backlash. The adjustment of drivepinion height and final drive gear backlash should be repeated until the toothcontact patterns are similar to the standard tooth contact pattern.
2.
When you cannot obtain a correct pattern, the drive gear and drive pinionhave exceeded their limits. Both gears should be replaced as a set.
Rear Differential Carrier Components and Components Location
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