Repair procedures: Reassembly

Install the spacer on the back of the side gear and then install the pinion gear (A) in the differential case.

Fig 1: Installing Pinion Gear In Differential Case
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
- When installing a new side gear, use a spacer of medium thickness [0.93-1.00 mm (0.3366-0.0394 in.)].
- Do not reuse the lock pin.
- The lock pin head must be sunk below the flange surface of the differential case.
Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears (B) by turning them.
Insert the pinion shaft (A).

Fig 2: Installing Pinion Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Measure the backlash between the side gears and pinions.
Standard value :

0.025-0.0150 mm (0.00095-0.00057 in)
If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.
CAUTION: Adjust the backlash of both side gears to the same specification.
Align the pinion shaft (C) lock pin hole with the case lock pin hole and insert the lock pin (B).
CAUTION:
- Do not reuse the lock pin.
Fig 3: Identifying Pinion Shaft Lock Pin Hole With Lock Pin
Courtesy of KIA MOTORS AMERICA, INC.
Install the tapered roller bearing on both sides of the differential case.
CAUTION: When press-fitting the bearing, press on the inner race only.

Fig 4: Pressing Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Apply ATF to the entire threads of the bolts. Tighten to specifications using the sequence shown in the illustration.
TORQUE : 127.5~137.3Nm (13~14 Kgf.cm, 94.0~101.3Ib.ft)

CAUTION: If a bolt is reused, remove the old sealant from the threads.

Fig 5: Identifying Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.