Repair procedures: Reassembly

Reassemble the spacer, side gear, washer, pinion and pinion shaft
1. Connect the side gear with the spacer, and install the side gear into differential case.
  NOTE: Use a spacer of neutral thickness.
  0.037-0.039in(0.93-1.00mm) for a new side gear
2. Connect the washer to the pinion and install them simultaneously at the point so that they may lock with the side gear.
  
  Fig 1: Connecting Washer To Pinion
  Courtesy of KIA MOTORS AMERICA, INC.
3. Insert the pinion shaft(A).
  
  Fig 2: Inserting Pinion Shaft
  Courtesy of KIA MOTORS AMERICA, INC.
4. Chaeck the side gear pinion backlash and install a proper spacer.
  Standard value :0.00098-0.0059in (0.025-0.150mm)
  
  NOTE: Adjust backlashes at both sides to be within standard value.
  
  Fig 3: Checking Side Gear Pinion Backlash
  Courtesy of KIA MOTORS AMERICA, INC.
Install the lock pin(A).
1. Install the lock pin as shown in the illustration.
  
  Fig 4: Installing Lock Pin
  Courtesy of KIA MOTORS AMERICA, INC.
Install the differential drive gear.
Apply the ATF to the entire threads of the bolts. Tighten to specifications using the sequence shown in the illustration.

Fig 5: Identifying Differential Drive Gear Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Using the special tool(09493-2F200) and press, install the taper roller bearing(A).

Fig 6: Installing Taper Roller Bearing Using Special Tool (09493-2F200)
Courtesy of KIA MOTORS AMERICA, INC.