Diagnosis & Overhaul: Components: Differential: Reassembly

Set speedometer drive gear onto ring gear and case assembly.

Fig 1: Setting Speedometer Drive Gear Onto Ring Gear And Case Assembly
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Do not reuse side bearings if they were removed.
Press side bearing (side opposite ring gear) into ring gear and case assembly with SST (0K990 175 AA1) or equivalent.
Press on other side bearing (ring gear side) in same manner.

Fig 2: Pressing On Other Side Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Install pinion gears and thrust washers into case.
Install pinion shaft.

Fig 3: Installing Pinion Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Install spring pin, and stake hole to prevent spring pin from coming out of gear case.

Fig 4: Staking Hole To Prevent Spring Pin From Coming Out
Courtesy of KIA MOTORS AMERICA, INC.
Install thrust washers and side gears into gear case at same time, then rotate them around pinion gears and align them with driveshaft holes.
NOTE: Be certain that both side gears are centered in their respective driveshaft holes. If not, remove both side gears and re-install them.

Fig 5: Installing Thrust Washers And Side Gears Into Gear Case
Courtesy of KIA MOTORS AMERICA, INC.
Measure backlash of side gears and pinion gears as follows:
1. Install left and right driveshafts in differential assembly.
2. Support driveshafts on V-blocks.
3. Measure backlash of both pinion gears.
Backlash:

Standard: 0.001-0.004 in (0.025-0.1 mm)

Maximum: 0.020 in (0.5 mm)
If backlash is not within specification, replace differential assembly.

Fig 6: Measuring Backlash
Courtesy of KIA MOTORS AMERICA, INC.