SPORTAGE(AL) >1999 > G 2.0 DOHC > Driveshaft and axle

Transcription

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SPECIAL TOOLS
Rear Axle
K95U-5005-GAxle
removal attachment
For removing axles
DIFFERENTIAL(Rear Axle)
K94U-0001-H
Universal handle
K95B-5006-D
Drive pinion model
For bearing and seal
installers
K95B-5004-D
Side bearing installation
attachment
For adjusting drive pinion
height
K95B-5005-D
Pinion gauge tube
For installing side
bearings
K95B-5001-D
Front bearing outer race
installation attachment
For adjusting drive pinion
height
K95B-5007-D
Carried diameter gauge
For installing front bearing
outer race
K95B-5003-B
Oil seal installation
attachment
For measuring carrier
diameter
K95U-0003-G
Drive tube
For installing bearings and
seals
For installing oil seals
K95B-5000-D
Rear bearing outer race
installation attachment
For installing rear bearing
K95B-5013-D
Companion flange holder
http://www.kiatechinfo.com/viewer/content.asp?IsPrint=true&imgnum=1&print_title=...
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outer race
For removing lock nut
K95B-5002-D
Rear bearing installation
attachment
K95U-0004-G
Slide hammer
For installing rear bearing
Universal
Front Axle
K95B-5011-A
For installing knuckle
needle bearing
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GENERAL SPECIFICATIONS
Starting Torque
2.6-8.7 lb·in (0.29-0.98 N·m)
Front Driveshaft Flange to Transfer
36-43 lb·ft (49-59 N·m)
Driveshaft Flange to Front Differential
25-27 lb·ft (34-37 N·m)
Rear driveshaft Flange to Transfer
36-43 lb·ft (49-56 N·m)
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COMPONENTS
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INSPECTION
Halfshafts
1. Inspect for broken or loose CV joint boots.
2. Test for loose halfshaft splines. By grasping the halfshafts and tugging up and down and fore and aft.
3. Also inspect for bent or broken halfshafts.
INSPECTION
Gear Oil
1. Add gear oil if oil level is not at filler hole.
2. Install filler plug with new washer.
Tighten filler plug to 35 lb-ft (47 N·m).
DISASSEMBLY
Halfshafts
Secure the CV joint in a vise with protective cover, such as copper, on the vise jaw. Be careful that dust or
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other foreign material does not enter the joint during repair. Do not disassemble the wheel side CV joint. Do
not wash joint in solvent unless it is to be disassembled.
1. Inspect boot and clamp for damage.
2. Pry up differential side boot locking clamps using a screwdriver and pliers.
3. Remove boot clamp and slide boot along shaft to expose the CV joint.
4. Mark shaft and the outer ring for identical installation position.
5. Remove the stopper ring with a screwdriver.
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6. Mark the shaft, cage, and inner ring for identical installation position.
7. Remove the snap ring with snap-ring pliers.
8. Remove the cage assembly.
9. Remove the ball bearings.
10. Mark the inner ring and cage for identical assembly position.
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11. Turn the cage about 30 degrees and separate it from the inner ring.
12. Wrap the wheel side splines with suitable tape and remove the boot.
13. If necessary, remove the dust cover with a plastic hammer.
REASSEMBLY (LH)
1. On differential end, install (if removed) a new dust cover with a plastic hammer.
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2. If not already wrapped, wrap the wheel side splines with suitable tape and install a new boot with a new
clamp.
The wheel side and differential side boots are not identical.
3. Align disassembly reference marks and put ball bearings into the inner ring.
4. Install the cage, inner ring and ball assembly to the halfshaft in the direction shown.
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Install the cage with the big end facing the snap ring groove. If installed in reverse, the drive shaft may
become disengaged.
5. Using snap-ring pliers, install a new snap ring into the halfshaft groove.
REASSEMBLY (RH)
1. For wheel end, install the cage on the inner ring and turn about 30 degrees with respect to the inner ring.
2. Fit the ball bearings through the cage into the ball grooves of the inner ring.
3. Apply yellow joint grease to the cage, inner ring, and ball bearings.
4. Align reference installation marks and install a new snap and stopper ring.
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5. Install boot with a new boot clamp:
A. Using pliers, fold boot clamp.
B. Bend the clamp clips to lock clamp in place.
Always use new clamps and install clamp crimp-over in opposite direction of halfshaft forward rotation.
6. Using pliers, install new clip onto differential half shaft en groove.
REMOVAL
Halfshafts
1. Remove six bolts and take off free wheel hub body.
2. Using snap ring pliers, remove axle snap ring retainer and spacer.
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3. Pry out fixed cam assembly.
4. Remove two bolts and remove brake caliper from brake rotor. Temporarily tie caliper to vehicle frame with
wire.
5. Remove the upper control arm link lock bolt, spring washer and nut.
6. Remove tierod end cotter pin and using a ball joint puller, remove tierod end from steering knuckle.
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7. Loosen the drop link lower lock nut.
8. Loosen the drop link upper four lock nuts.
9. Using a rubber hammer, open up the drop link fork.
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10. Mark halfshaft for identical installation position.
11. Using suitable tool, pry halfshaft from differential housing.
Be sure and mark the driginal alignment of the halfshaft to their mounting flanges with paint or a suitable
punch.
INSTALLATION
Halfshafts
1. Align the halfshaft-differential assembly reference marks and insert the halfshaft into differential housing.
2. Tighten the four upper drop link lock nuts.
3. Tighten the lower drop lock nut.
After the halfshafts are installed in the differential and the drop link is tightened, refer to “Steering Knuckle”,
“Wheel Bearings”, and “Free Wheel Hub” in this section to complete installation.
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COMPONENTS
DRIVE SHAFT ASSEMBLY
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DIAGNOSIS
Problem
Vibration
Possible Cause
Action
Bent drive shaft
Replace
Left/right universal joint snap rings not symmetrical
Adjust
Loose yoke installation
Tighten
Worn or damaged universal joint bearing
Replace
Universal joint snap ring
Tighten
Noise
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INSPECTION
Universal Joint
1. Make sure snap rings are completely seated and firm.
2. Check starting torque with suitable gauge. If the starting torque is not within the specified range, adjust by
changing the snap rings to greater or lesser thickness.
Stating torque: 2.6-8.7 lb-in (0.29-0.98 N·m)
Thickness:
Part no.
inch
(mm)
1757 25 171
0.0480
(1.22)
1757 25 172
0.0488
(1.24)
1757 25 173
0.0496
(1.26)
1757 25 174
0.0504
(1.28)
1757 25 175
0.0512
(1.30)
1757 25 176
0.0520
(1.32)
1757 25 177
0.0528
(1.34)
1757 25 178
0.0535
(1.36)
1757 25 179
0.0543
(1.38)
REMOVAL
Drive Shaft Defrection
1. Raise and suitably support vehicle.
2. Place suitable index marks (reference marks) on the drive shafts and their matching transfer case and
differential input/output shafts.
3. Remove four nuts holding universal flange to transfer case.
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4. Remove four nuts holding universal flange to differential.
5. Remove drive shaft.
6. Inspect drive shaft for dents or other damage. If shaft appears damaged, replace it.
7. Inspect universal joints for smooth pivoting. If joints bind or appear tight, replace them as assemblies.
INSTALLATION
Universal Joint
1. Align index marks on the driveshaft.
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2. Connect front driveshaft flange to companion flange on transfer.
(1) Align index marks on the flange and connect the flanges with four bolts and nuts.
(2) Tighten the bolts and nuts.
Tightening torque : 36-43 lb·ft (49-59 N·m)
3. Connect driveshaft flange to companion flange on front differential.
Tightening torque 25-27 lb·ft (34-37 N·m)
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4. Connect rear driveshaft flange to companion flange on transfer.
Tightening toque : 36-43 lb·ft (49-56 N·m)
5. Connect driveshaft flange to compaion flange on rear differential.
Tightening torque 25-27 lb·ft (34-37 N·m)
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DISASSEMBLY
Universal Joint
To prevent drive damage, use vise pads.
1. Place drive shaft in vise.
2. For reassembly purposes, place index marks (reference marks) on the drive shaft, spider and yoke.
3. Using a suitable screwdriver, remove and discard all snap rings.
4. Lightly tap with a suitable hammer to remove bearings from the yoke.
5. Remove the yoke.
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6. Using a suitable drift punch and hammer, remove the spider bearings
REASSEMBLY
Universal Joint
1. Before assembly, coat the inside of the bearing cap, roller, and grease groove hole of the spider with lithium
base grease.
Align the drive shaft and spider index marks.
2. With drive in a suitable vise, place spider in drive yoke. Using a plastic hammer, tap bearing caps onto spider
ends.
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3. Place mating yoke over open spider ends and, using a plastic hammer, tap remaining bearing caps onto
spider ends.
4. Install new snap rings. All four snap rings must be the same thickness.
INSPECTION
Universal Joint
1. Make sure snap rings are completely seated and firm.
2. Check starting torque with suitable gauge. If the starting torque is not within the specified range, adjust by
changing the snap rings to greater or lesser thickness.
Stating torque: 2.6-8.7 lb-in (0.29-0.98 N·m)
Thickness:
Part no.
inch
(mm)
1757 25 171
0.0480
(1.22)
1757 25 172
0.0488
(1.24)
1757 25 173
0.0496
(1.26)
1757 25 174
0.0504
(1.28)
1757 25 175
0.0512
(1.30)
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1757 25 176
0.0520
(1.32)
1757 25 177
0.0528
(1.34)
1757 25 178
0.0535
(1.36)
1757 25 179
0.0543
(1.38)
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Starting Torque : 4-12 lb·in (0.4-1.4 N·m)
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GENERAL DESCRIPTION
1. A Hypoid-type differential ring and pinion gear set transmits the engine’s driving force to the front wheels
through halfshafts. The gear set and a single axle are enclosed in a modified Salisbury type housing which is
bolted to the vehicle. The left and right halfshafts are attached to the differential and drive wheels by constant
velocity (CV) joints. Freewheel auto-locking hubs are provided.
A limited-slip differential is not an option for the front drive axle.
The front hubs are not interchangeable between 4WD models. 2WD Front Hubs do not include two
attaching points for the 4WD Auto-Locking Front Hubs.
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INSPECTION
FREE WHEEL HUB-VACUUM
1. Check if 4WD signal turns on when the shift lever is moved into 4WD position. Refer to ETM.
2. Check for any wear or damage to vacuum pipe, tube or hose and for any looness of the clip, clamp or band.
3. Disconnect vacuum hose from knuckle and then apply 550mmHg vacuum to knuckle vacuum pipe.
Check to see if vacuum holds with a minimum of 500mmHg after one minute.
4. If vacuum does not hold with a minimum of 500mmHg, then check the sealant.
If sealant is normal, replace free wheel hub body assembly.
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REMOVAL
Wheel Bearings
To remove wheel bearings, the free wheel hub must first be removed. Refer to “Free Wheel Hub” in this section.
1. Remove two bolts and remove brake caliper from brake rotor. Temporarily tie caliper to vehicle frame with
wire.
2. Remove two screws and take off brake rotor.
3. Using a lock nut wrench (or equivalent), remove lock nut.
4. Remove wheel bearing hub.
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5. Using a screwdriver, pry out oil seal from wheel bearing hub.
6. Remove inner and outer bearings from the wheel bearing hub.
7. Using a suitable drift punch, remove inner and outer bearing race.
REMOVAL
Steering Knuckle
To remove steering knuckle, the free wheel hub and wheel bearing hub must first be removed. Refer to “Free
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Wheel Hub” and Wheel Bearings” in this section.
1. Remove dust cover
2. Remove the upper control arm link lock bolt, spring washer and nut.
3. Remove tie rod end cotter pin and using a ball joint puller, remove tie rod end from steering knuckle.
4. Remove lower control arm cotter pin and using a ball joint puller, and remove control arm from steering
knuckle.
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5. Remove steering knuckle from vehicle and using a screwdriver, pry out inner oil seal.
6. Using a needle bearing puller, remove the needle bearing.
INSTALLATION
Wheel Bearings
1. Install inner bearing outer race and oil seal.
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2. Install outer bearing outer race.
3. Install dust cover with four screws.
4. Apply grease to both bearings and the oil seal lip.
5. Put wheel bearing hub assembly on steering knuckle.
Turn back and forth to verify correct bearing installation.
6. Screw lock nut up against wheel hub assembly and using a lock nut wrench, tighten nut to set bearing
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preload.
Bearing preload: 10 lb-in (1.3 N·m)
7. Put brake rotor on wheel bearing hub bolts and install the two retaining screws.
8. Mount dial indicator with plunger zeroed against brake rotor at 4.7 inch (12 cm) from rotor center.
9. Turn rotor and read dial indicator for runout dimension.
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Runout not to exceed 0.004 inch (0.10 mm)
10. Install brake caliper and tighten two bolts.
11. Align the free wheel hub fixed cam key with the lock nut groove and push on fixed cam assembly. Apply
grease to both ends of the snap ring.
12. Put spacer on the axle, then using suitable snap ring pliers, install axle retainer snap ring.
13. Apply sealant to free wheel hub body mounting surface.
14. Install and tighten, in two passes, six bolts in the order shown.
First pass: Tighten hub mounting bolts to 19 lb-ft (25 N·m).
Second pass: Tighten hub mounting bolts to 23 lb-ft (31 N·m).
INSTALLATION
Steering Knuckle
Required SST:
• Needle Bearing Installer: K95B-5011-A
1. Using SST K95B-5011-A, install bearing.
2. Install new oil seal.
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3. Apply grease to the needle bearing and seal lip.
4. If spacer was removed, apply grease to both sides and install on halfshaft end.
5. Put steering knuckle on the halfshaft end with upper and lower ball joints in mounting holes.
6. Attach lower control arm, tighten lock nut, and install cotter pin.
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Tighten lock nut to 110 lb-ft (148 N·m).
7. Attach tierod end to knuckle, tighten nut, and install cotter pin.
Tighten lock nut to 27 lb-ft (36 N·m).
8. Insert upper control arm link lock bolt with spring washer and tighten nut.
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Tighten nut to 36 lb-ft (49 N·m).
To assemble wheel bearing hub, brake caliper, brake rotor, and free wheel hub, refer to “Free Wheel Hub”
and “Wheel Bearings” in this section.
INSPECTION
FREE WHEEL HUB-VACUUM
1. Check if 4WD signal turns on when the shift lever is moved into 4WD position. Refer to ETM.
2. Check for any wear or damage to vacuum pipe, tube or hose and for any looness of the clip, clamp or band.
3. Disconnect vacuum hose from knuckle and then apply 550mmHg vacuum to knuckle vacuum pipe.
Check to see if vacuum holds with a minimum of 500mmHg after one minute.
4. If vacuum does not hold with a minimum of 500mmHg, then check the sealant.
If sealant is normal, replace free wheel hub body assembly.
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REMOVAL
Free Wheel Hub
1. Remove six bolts and take off free wheel hub body
2. Using snap ring pliers, remove axle snap ring retainer and spacer.
3. Pry out fixed cam assembly.
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INSTALLATION
Free Wheel Hub
1. Align the fixed cam key with the lock nut groove and push on fixed cam assembly.
2. Put spacer on the axle, then using suitable snap ring pliers, install axle retainer snap ring. Apply grease to
both ends of the snap ring.
3. Apply sealant to free wheel hub body mounting surface.
4. Install hub and tighten six bolts, in two passes, in the order shown.
First pass: Tighten hub mounting bolts to 19 lb-ft (25 N·m).
Second pass: Tighten hub mounting bolts to 23 lb-ft (31 N·m).
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COMPONENTS
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DIAGNOSIS
AXLE
Problem
Possible Cause
Action
Improperly adjusted wheel bearing play
Tighten or replace
Worn or damaged wheel bearing
Replace
Replace
Tighten or replace
Tighten or replace
Steering wheel vibration
Abnormal noise
Excessive steering wheel
play
HALF SHAFTS
Problem
Possible Cause
Action
Worn CV joint
Replace
Poorly greased CV joint or spline
Replace
Excessive spline backlash
Grease or replace
Worn or damaged CV ball bearing
Replace
Damaged boot
Replace
Loose boot band
Replace
Excessive grease
Repair
Abnormal noise
CV boot leaking grease
DIFFERENTIAL
Problem
Possible Cause
Action
Insufficient oil
Add oil
Incorrect oil
Replace
Final gear backlash out of adjustment
Adjust
Final gear teeth out of adjustment
Adjust
Worn or damaged side bearing
Replace
Worn or damaged final gear
Replace
Worn or damaged pinion bearing
Replace
Worn or damaged pinion and side gear
Replace
Seized side gear
Replace
Worn side gear spline
Replace
Loose companion flange nut
Tighten
Worn side gear thrust washer
Replace
Worn pinion shaft
Replace
Improperly adjusted side bearing preload
Adjust
Improperly adjusted drive pinion bearing preload
Adjust
Worn output shaft spline
Replace
Insufficient differential oil
Add oil
Abnormal noise
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Insufficient gear backlash
Adjust
Excessive bearing preload
Replace
Excessive differential oil
Drain oil
Clogged differential housing breather
Repair
Loose differential carrier
Tighten
Worn or damaged oil seal
Replace
Heat build up
Oil leakage
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REMOVAL
1. Drain gear oil into suitable container.
2. Remove the drive shaft. Refer to propeller shaft.
3. Remove halfshafts. Refer to “Free Wheel Hub”, “Wheel Bearings”, and “Steering Knuckle” in this section.
4. Jack up the differential and remove three differential mounting bolts.
DISASSEMBLY
Output Shaft
1. Remove bearing housing bolts.
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2. Remove output shaft from differential housing.
3. Remove bearing housing oil seal.
4. Remove axle clip using pliers.
5. Pry out oil seal with a screwdriver.
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6. Using a hydraulic press, remove bearing housing from the output shaft.
7. Using a hydraulic press, remove bearing using SST K95B-5014-A from output shaft.
8. Inspect:
A. Output shaft for damage.
B. Bearing for roughness or noise.
C. Oil seal for damage.
D. Bearing housing for cracks.
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REASSEMBLY
Output Shaft
1. Install oil seal into bearing housing.
2. Using a hydraulic press, install bearing onto output shaft using SST K95B-5014-A.
3. Using a hydraulic press, install shaft with bearing into bearing housing.
4. Install new bearing housing O-ring.
5. Install new clip onto output shaft groove.
6. Insert output shaft into differential housing.
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7. Install and tighten four bolts and nuts.
Tighten nuts to 34 lb-ft (46 N·m).
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SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Wheel Bearing Hub
Mounting Bolts
Differential
1 st Pass
19 lb-ft (25 N·m)
2 nd Pass
23 lb-ft (31 N·m)
Steering Knuckle
Lower Control Arm Lock Nut
110 lb-ft (148 N·m)
Tierod End Lock Nut
27 lb-ft (36 N·m)
Upper Control Arm Lock Nut
36 lb-ft (49 N·m)
Gear OIL filler Plug
35 lb-ft (47 N·m)
Output Shaft Oil seal Filler Plug
35 lb-ft (47 N·m)
Housing Nut
34 lb-ft (46 N·m)
Nut A
48 lb-ft (65 N·m)
Nut B
63 lb-ft (85 N·m)
Assembly
Axle
Bearing Preload (install the oil seal, apply grease)
7.812-12.152 lb-in (0.8821.372 N·m)
Type
Semi-float
RH
27.3 inch (693 mm)
LH
25.5 inch (647 mm)
Shaft Length
Differential
Reduction Gear
Hypoid gear
Differential Gear
Straight bevel gear
Final Gear Ratio
4.778:1
Joint Type
Constant Velocity
Halfshaft
RH
23.4 inch (596.2 mm)
LH
20.8 inch (528.7 mm)
Shaft Length
Shaft Diameter
1.07 inch (27.1 mm)
LUBRICANTS
Grade
API GL-5
Above 0°F (18°C)
SAE 90
Below 0°F (18°C)
SAE 80W
Oil
Viscosity
Amount
1.3 qts (1.2 L)
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GENERAL DESCRIPTION
1. The solid rear axle layout is identical for 2WD, 4WD, vehicles. The rear axle consists of right and left axle
shafts that have their inner ends connected to a hypoid type of differential. The axle housing is located to the
frame from front to back with one upper and two lower trailing links. It is located from side to side with a single
Panhard rod. The rearaxle is suspended from the frame with coil springs and tubular shock absorbers.
To take full advantage of the DOHC engine’s greater torque, the differential in these vehicles has a ring and
pinion gear ratio that is numerically higher. As an option, the 4WD vehicles with the DOHC engine can be
equipped with a limited slip differential.
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COMPONENTS
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REMOVAL
Axle Shaft
Required SST:
• Axle Attachment: K95U-5005-G
• Slide Hammer: K95U-0004-G
1. Raise vehicle and remove wheels.
2. Remove four nuts and take off brake drum.
3. Remove four nuts holding oil seal retainer flange.
4. Using SST K95U-5005-G and K95U-0004-G, remove axle shaft assembly.
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INSTALLATION
Axle Shaft
Axle shafts are left-hand and right-hand. The left-hand shaft is 28.2 inches (717 mm) long: the right-hand shaft is
30.0 inches (763 mm) long.
1. If removed, place backing plate/brake assembly on four bolts at end of axle housing.
2. Insert the axle shaft assembly into the axle housing.
Take care not to damage oil seal.
3. Move axle back and forth until axle spline mates with differential side gear spline. Make sure holes in oil seal
retainer flange fit over axle housing bolts.
4. Install four nuts onto axle housing nuts.
Tighten nuts to 74 lb·ft (100 N·m)
5. Install brake drum with four nuts.
6. Install wheels and lower vehicle.
Tighten nuts to 74 lb·ft (100 N·m)
DISASSEMBLY
1. Using a hammer and chisel to drive the lock nut and lock washer, remove the assembly from the axle.
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• Turn the lock nut of right-hand shaft counterclockwise.
• Turn the lock nut of left-hand shaft clockwise.
• The left-hand lock nut is marked on the "L".
INSPECTION
1. Check for bent axle shaft using “V” blocks and dial indicator.
Maximum runout: 0.04 inch (1.0 mm)
2. Check for worn or damaged axle shaft spline.
3. Check for worn or damaged wheel bearing.
4. Check for damaged oil seal.
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REASSEMBLY
If axle is to be replaced, replace with complete assembly.
1. Slide oil seal retainer, oil seal, rib ring, and wheel bearing on axle shaft.
2. Install new lock nut onto new lock washer.
Tighten lock nuts to 220 lb·ft (300 N·m)
• Turn the lock nut of right-hand shaft clockwise.
• Turn the lock nut of left-hand shaft clockwise.
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DIAGNOSIS
AXLE
Problem
Possible Cause
Action
Bent axle casing
Replace
Bent axle shaft
Replace
Replace
Worn axle shaft spline
Replace
Replace
Abnormal noise
Oil leakage
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REPLACEMENT
Gear Oil
1. Remove drain plug and drain oil into suitable container.
2. Install drain plug with new washer.
3. Add gear oil until level reaches filler hole.
Oil capacity: 1.3 US qt (1.2 Liters)
Oil specification above 0°F (18°C): API GL-5, SAE 9 0
Oil specification below 0°F (18°C): API GL-5, SAE 8 0
4. Install the filler plug with new washer.
Output Shaft Oil Seal
1. Drain gear oil. Refer to Gear Oil” in this section.
2. Remove RH halfshaft. Refer to “Free Wheel Hub”, “Wheel Bearings”, and “Steering Knuckle” in this section.
3. Using a screwdriver, pry out oil seal.
4. Install new oil seal.
5. Install halfshaft. Refer to “Free Wheel Hub”, “Wheel Bearings”, and “Steering Knuckle” in this section.
7. Install the filler plug with new washer.
INSTALLATION
1. Install differential assembly.
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Tighten nut A 48 lb-ft (65 N·m).
Tighten nut B 63 lb-ft (85 N·m).
2. Install RH and LH halfshafts. Refer to “FREE wheel Hub”, “Wheel Bearings”, and “Steering Knuckle” in this
section.
3. Install drive shaft. Refer to Propeller Shaft.
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COMPONENTS
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REMOVAL
Differential Carrier
1. Remove the axle shafts. Refer to “Axle Shaft” in this section.
2. Drain gear oil and remove driveshaft. Refer to “Pinion Oil Seal Replacement” in this section.
3. Remove ABS sensor mounting bolt.
4. Remove eight bolts and remove differential carrier assembly.
REMOVAL
Differential Housing
1. Raise vehicle; remove wheels and brake drums.
2. Remove axle shafts.
3. Remove the drain plug and drain gear oil into suitable container. Install drain plug.
Tighten drain plug to 27 lb·ft (36 N·m)
4. Remove ABS sensor.
5. Using a line wrench, disconnect brake line from differential housing splitter block.
6. Mark for identical installation position and remove driveshaft.
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7. Remove emergency brake cable restraining strap.
8. Using a line wrench, disconnect brake line from each brake assembly.
9. Move backing plate with attached brake assembly aside and tie it to the chassis with wire.
10. Support the housing with a jack.
11. Remove both shock absorber lower mounting bolts.
12. Remove both lower trailing link-to rear axle housing bolts.
13. Remove the upper bolt.
14. Remove the panhard bar-to-rear axle housing bolt.
15. Lower jack and remove coil springs and rubber seats.
16. With housing on a suitable work surface, remove differential carrier.
17. Remove brake line from housing.
18. Remove breather.
INSTALLATION
Side Bearing
Required SST:
• Universal Handle: K94U-0001-G
• Bearing Installer: K95B-5004-D
• Adjuster Nut Wrench: K95B-0001-U
• Carrier Diameter Gage: K95B-5007-D
Install all parts into their original positions using disassembly reference marks.
1. Using SST K94U-0001-G, K95B-5004-D, and a hydraulic press, install side bearing.
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2. Install the differential gear assembly into the carrier.
Tighten end bearing cap bolts to 10 lb-ft (13 N·m)
3. Mount a dial indicator with its plunger contacting a ring gear tooth facing.
4. With indicator zeroed at one direction of the ring gear maximum rotation (the locked pinion will prevent the
ring gear moving beyond any backlash), reverse the ring gear rotation. The indicator reading is the backlash
value.
5. Using SST K95B-0001-U, adjust left and right adjusters equally until correct backlash is achieved.
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Backlash: 0.0035-0.0043 inch (0.09-0.11 mm)
If SST K95B-5007-D will not fit over carrier measuring pads, carrier will not fit into the differential housing.
6. As shown, use SST K95B-5007-D to inspect differential carrier diameter. If SST K95B-5007-D does not fit
over measuring pads, side bearing preload must be relieved until it does.
7. Tighten side bearing caps.
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Tighten bolts to 31 lb-ft (42 N·m)
8. Measure the ring gear backlash.
Backlash: 0.0035-0.0043 inch (0.09-0.11 mm)
Differential Carrier
1. Apply RTV sealant (or equivalent) and install the differential carrier assembly
Tighten M8 bolts to 18 lb-ft (24 N·m)
2. Install ABS sensor with retainer bolt.
Tighten ABS retainer bolt to 15 lb-ft (20 N·m)
3. Install axle shafts.
4. Install brake assembly.
5. Install brake drum.
6. Install wheels and lower vehicle.
7. Install driveshaft.
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Tighten transfer-to-universal joint nuts to 40 lb-ft (54 N·m)
Tighten differential-to-universal joint nuts to 2 lb-ft (28 N·m)
8. Fill differential with oil to filler hole level.
Oil capacity: 1.6 quarts (1.5 L)
Oil specification above 0°F (-18°C): API GL-5, SAE 90
Oil specification below 0°F (-18°C): API GL-5, SAE 80
9. Install the filler plug with a new washer.
Tighten filler plug to 27 lb-ft (36 N·m)
10. Install differential drain plug with new washer.
INSTALLATION
1. Attach brake line to housing.
2. Apply RTV sealant (or equivalent) and install differential carrier assembly.
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3. Using a suitable jack, place rear axle housing in preliminary installation position and install coil springs with
upper and lower rubber seats
4. Jack housing up into final mounting position.
5. Attach panhard bar to axle hosing and tighten bolt.
6. Attach upper trailing link and tighten bolt.
7. Attach both lower trailing links and tighten bolts.
8. Attach both shock absorbers and tighten bolts.
Tighten panhard bar, trailing links and shock absorber mounting bolts to 66 lb-ft (90 N·m)
9. Place brake assembles in mounting position.
10. Install nuts.
Tighten nuts to 74 lb-ft (100 N·m)
11. Install breather.
12. Using a line wrench, attach brake line to both brake assemblies.
13. Attach emergency brake cable restraining strap to chassis.
14. Install both axles. Refer to “Axle” in this section.
15. Using a line wrench, attach brake line to rear axle housing splitter block.
16. Install ABS sensor.
17. Align reference marks and install driveshaft.
18. Fill differential with oil to filler hole level.
Oil capacity: 1.6 quarts (1.5L)
20. Bleed the brake system. Refer to Brake System.
DISASSEMBLY
Carrier
1. Mount differential carrier assembly on a suitable work stand.
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2. Mark both differential side bearing caps and carrier housing for identical installation position.
3. Remove the six bolts, two locking plates, and both bearing caps.
4. Remove side bearing screws and side bearing outer races. Mark for identical installation as shown.
Side Bearing
1. Mark bearings and carrier case for identical installation position.
2. Using a bearing puller, remove side bearings from carrier.
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Ring Gear
1. Secure carrier assembly in a vise, using vise jaw caps to protect carrier from damage. Secure with the ring
gear as shown.
2. Mark the ring gear and differential case for identical installation position.
3. Remove the ring gear mounting bolts and ring gear.
If LSD-equipped, restrain ABS sensor ring-plate to spring-loaded carrier while removing cross recess
screws.
4. Unscrew four cross recess screws to remove ABS sensor ring-plate.
If LSD replacement, no further disassembly required.
Pinion Shaft
1. Using a suitable drift punch, drive out pinion shaft lock pin.
2. Mark side and pinion gears for identical installation position.
3. Remove pinion shaft, pinion gears, side gears, thrust washers, and if equipped, LSD springs and clutch
plates.
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Companion Flange
Required SST:
• Companion Flange Holder: K95B-5013-D
1. Using SST K95B-5013-D, remove lock nut and washer.
2. Remove the companion flange.
Pinion
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1. Drive the pinion out of the carrier with a plastic hammer.
2. Remove oil seal.
3. Remove the front bearing.
To prevent pinion damage, support pinion so that when the rear bearing comes off the pinion shaft, the
pinion will not fall to the floor.
4. Using a bearing splitter and a hydraulic press, remove rear bearing and spacer.
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5. Using suitable drift punch, alternately placed in two opposing carrier grooves, remove front and rear outer
bearing races.
Mark the bearing races for identical installation.
Differential Parts
After cleaning, check for the following and replace parts if necessary:
1. Poor meshing, worn or damaged ring gear and drive pinion.
Replace ring and pinion as a set.
2. Worn or damaged bearings.
3. Damaged adjustment shim.
4. Damaged oil seal.
5. Damaged carrier and differential housing.
6. Worn or damaged side gear and thrust washer.
7. Incorrect crush spacer length.
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Length of crush spacer: 2.16-2.21 inches (54.80-56.09 mm)
REASSEMBLY
Differential
If LSD replacement, begin assembly procedure at “Ring Gear Assembly”.
1. Mount thrust washers on the side gears.
2. Install pinion gears, side gears, and if equipped, LSD clutch plates and springs into carrier.
3. Install pinion shaft.
Do not install pinion lock pin here.
4. Adjust side and pinion gear backlash as follows:
(1) Mount the gear case in a vise with dial indicator plunger touching ring gear.
(2) Look one of the side gears.
(3) Read dial indicator while turning the pinion gear.
(4) Change thrust washer thickness until dial indicator reading does not exceed maximum value.
Identification mark
Washer thickness: inch (mm)
0
0.0787 (2.00)
05
0.0807 (2.05)
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1
0.0827 (2.10)
15
0.0846 (2.15)
2
0.0866 (2.20)
Maximum backlash: 0.008 inch (0.2 mm)
5. Install pinion shaft lock pin.
6. Using a suitable punch, stake lock pin in place.
Ring Gear
1. Mount ABS sensor ring onto carrier with four cross recess screws.
2. Apply thread locking compound to ring gear back face mounting holes.
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3. Bolt ring gear onto the gear case. When torquing bolts, alternate sides to prevent any warping.
Tighten ring gear mounting bolts to 56 lb-ft (76 N·m)
ADJUSTMENT
Pinion Height
Required SST:
• Bearing Outer Race Installer: K95B-5000-D
• Bearing Outer Race Installer: K95B-5001-D
• Drive Pinion Model: K95B-5006-D
• Pinion Gauge Tube: K95B-5005-D
1. Using SST K94U-0001-G and K95B-5001-D, install front bearing outer race.
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2. Using SST K94U-0001-G and K95B-5000-D, install inner bearing outer race.
3. Put the front and rear bearings onto the drive pinion model SST K95B-5006-D.
4. Install the pinion model assembly SST K95B-5006-D into the carrier as shown.
5. Install pinion gauge tube SST K95B-5005-D into the carrier as shown.
6. Install bearing caps and hand-tighten bolts.
7. With the model’s gauge block 90 degrees to the gauge tube, measure the space between the gauge block
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and the gauge tube.
8. From the available spacers, choose and install a pinion spacer (bevel next to pinion gear) with a thickness
that equals the just-measured space plus 0.078 inch (2 mm).
Available spacers
ID Mark
Thickness: inch (mm)
ID Mark
Thickness: inch (mm)
08
0.1213 (3.08)
29
0.1295 (3.29)
11
0.1224 (3.11)
32
0.1307 (3.32)
17
0.1248 (3.17)
38
0.1331 (3.38)
20
0.1260 (3.20)
41
0.1343 (3.41)
23
0.1271 (3.23)
44
0.1353 (3.44)
26
0.1283 (3.26)
47
0.1366 (3.47)
9. Remove pinion model and gauge tube.
Pinion Preload
Required SST:
1. Put spacer on pinion shaft and using a press, install pinion rear bearing.
Do not install the oil seal here.
2. Install pinion, crush spacer, front bearing, and companion flange into carrier housing.
3. Hold assembly in place with lock nut hand tightened and hand turn companion flange to seat the pinion
bearings.
4. Using SST K95B-5013-D and a suitable torque wrench, tighten lock nut.
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5. Measure the pinion bearing preload by turning the pinion with a torque wrench.
Pinion bearing preload: 10 lb-in (1.1 N·m)
Tighten nut to no more than 210 lb-ft (284 N·m), but not less than 94 lb-ft (128 N·m)
6. Remove the lock nut, washer, and companion flange.
7. Using SST K95U-0003-G and K95B-5003-D, install new oil seal.
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8. Install companion flange, washer, and new lock nut.
9. Tighten lock nut.
Tighten nut to no more than 210 lb-ft (284 N·m), but not less than 94 lb-ft (128 N·m).
10. Measure run-out of the companion flange.
Measure run-out: 0.0027 inch (0.07 mm)
Ring Gear-to-Pinion Gear Contact
1. Coat both surfaces of 6-8 ring gear teeth with Prussian blue or white grease.
2. Rotate the marked ring gear teeth back and forth past the pinion.
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3. If the ring gear pinion marks are not near the center of the ring gear teeth, disassemble, and adjust pinion in
or out.
(1) Heel and face contact marks: use thicker pinion spacer to move pinion in.
(2) Toe and flank contact marks: use thinner pinion spacer to move pinion out.
Tighten lock plate bolts to 16 lb-ft (21 N·m)
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FASTENER TIGHTENING SPECIFICATIONS
ABS Retainer Bolt
15 lb-ft (20 N·m)
Axle Housing Nuts
74 lb-ft (100 N·m)
Axle shaft lock nuts
220 lb-ft (300 N·m)
Brake Assembly Mounting Nuts
74 lb-ft (100 N·m)
Differential-to-Universal Joint Nuts
21 lb-ft (28 N·m)
Drain Plug
27 lb-ft (36 N·m)
Filler Plug
27 lb-ft (36 N·m)
Lock Plate Bolts
16 lb-ft (21 N·m)
M8 Bolts
18 lb-ft (24 N·m)
M10 Bolts
38 lb-ft (51 N·m)
Panhard Bar Mounting Bolts
66 lb-ft (90 N·m)
Pinion Lock Nut
94-210 lb-ft (128-284 N·m)
Ring Gear Mounting Bolts
56 lb-ft (76 N·m)
Shock Absorber Mounting Bolts
66 lb-ft (90 N·m)
Side Bearing Cap Bolts
31 lb-ft (42 N·m)
Trailing Link Mounting Bolts
66 lb-ft (90 N·m)
Transfer-to-Universal Joint Nuts
40 lb-ft (54 N·m)
Reduction Gear
Hypoid gear
Differential Gear
Straight bevel gear
Final Gear Ratio
4.778 to 1
Differential
Grade
Oil
API GL-5
Above 0°F (-18°C)
SAE 90
Below 0°F (-18°C)
SAE 80W
Viscosity
Amount
1.6 qts (1.5 L)
RH
30.0 in. (763 mm)
LH
28.2 in. (717 mm)
Shaft Length
Axle Shafts
Shaft Diameter
1.3 in. (33 mm)
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DIAGNOSIS
Limited-slip Differential (LSD)
A vehicle equipped with a limited-slip differential will always have both wheels driving. If, while the vehicle is
beingserviced, only one wheel is raised off the floor and the rear axle is driven by the engine, the wheel on
the floor coulddrive the vehicle off the stand or jack.
Problem
Possible Cause
Action
Misassembled friction disc, plate or conical spring
Repair
Incorrect shim selection for gear sub-assemblies
Adjust
Replace
Misassembled friction disc, plate, conical spring
Repair
Incorrect shim selection for gear sub-assemblies
Adjust
Worn friction disc, plate, conical spring or pressure
ring
Replace
No differential operation
No LSD operation
INSPECTION
1. Jack up one wheel.
2. While the other wheel is on the floor, and using a torque wrench of at least 200 lb·ft (271 N·m), test the
breakaway torque required to start rotation. The torque required to start rotation should be at least 20 lb·ft (27
N·m). Normally, the initial breakaway torque will be higher than the continuous turning torque. The axle shaft
should turn with even pressure without binding throughout the test.
3. If the torque reading is less than specified or if driving tests reveal abnormal chatter, the differential case
should be replaced. Refer to “Differential” under “On-Vehicle Service” in this section.
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COMPONENTS
Gear Oil
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DIAGNOSIS
STANDARD DEFFERENTIAL
Problem
Possible Cause
Action
Insufficient oil
Add oil
Incorrect oil
Replace
Final gear backlash out of adjustment
Adjust
Final gear teeth out of adjustment
Adjust
Worn or damaged side bearing
Replace
Worn or damaged ring gear
Replace
Worn or damaged pinion bearing
Replace
Worn or damaged pinion and side gear
Replace
Seized side gear
Replace
Worn side gear spline
Replace
Loose companion flange nut
Tighten
Worn side gear thrust washer
Replace
Worn pinion shaft
Replace
Improperly adjusted side bearing preload
Adjust
Improperly adjusted drive pinion bearing preload
Adjust
Worn output shaft spline
Replace
Add oil
Insufficient gear backlash
Adjust
Excessive bearing preload
Replace
Excessive differential oil
Drain oil
Clogged differential housing breather
Repair
Loose differential carrier
Tighten
Replace
Abnormal noise
Heat buildup
Oil leakage
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REPLACEMENT
Gear Oil Level
1. Remove the filler plug and discard washer.
2. Add oil to the filler hole level.
3. Install filler plug with a new washer installed.
Gear Oil
1. Remove the drain plug and discard washer.
2. Drain the oil into a container.
3. Using a new washer, install the drain plug.
Tighten drain plug to 27 lb-ft (36 N·m)
4. Remove the filler plug and discard washer.
5. Add gear oil to the filler hole level.
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Pinion Oil Seal
Required SST:
• Oil Seal Installer: K95B-5003-D
1. Raise vehicle: remove wheels and brake drums.
2. Remove the drain plug and drain gear oil into suitable container.
3. Mark for identical installation position and remove driveshaft.
4. Using a pound-inch (N·m) torque wrench, measure and record the torque required to maintain rotation of the
pinion.
5. Using SST K95B-5013-D, remove pinion lock nut.
6. Remove companion flange.
7. Remove the oil seal.
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8. Install new oil seal using SST K95U-0003-G and K95B-5003-D. Apply a thin coat of gear oil to new oil seal.
9. Install companion flange.
10. Using an pound-inch (N·m) torque wrench and SST K95B-5013-D, install lock nut to torque preload reading
obtained when nut was removed or 8-14 lb-in (0.9-1.6 N·m). If reduced preload is required, a new crush
spacer must be installed.
11. Align reference marks and install driveshaft.
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Tighten transfer-to universal joint nuts to 40 lb-ft (54 N·m)
Tighten differential-to universal joint nuts to 29 lb-ft (39 N·m)
12. Add gear oil to the filler hole level.
13. Install the filler plug with a new washer installed.
14. Install brake drums and wheels, and lower vehicle.
1/29/2011

SPORTAGE(AL) >1999 > G 2.0 DOHC > Driveshaft and axle

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