Hyundai Kona Quiz
Propeller Shaft and Axle (2WD-FF)

Rear Differential Carrier Repair Procedures

In this manual: Propeller Shaft and Axle (2WD-FF)
General Information — 17Engine Mechanical System — 85Engine Electrical System — 50Emission Control System — 26Engine Control System/Fuel System — 152DCT (Dual Clutch Transmission) System — 50Four-Wheel Drive (4WD) System — 21Propeller Shaft and Axle (2WD-FF) — 28Suspension System (without ECS) — 32Steering — 21Restraints — 38Brake System — 64Body (Interior and Exterior) — 205Body Electrical System — 1Heating, Ventilation, and Air Conditioning — 66
53steps
~373min
5/5difficulty
11special tools
04080120160200127.594N·mlb·ft
Tightening torque found on this page
Done 0 of 53

Removal

  1. Loosen the wheel nuts slightly. Raise the vehicle and make sure it is securely supported.
  2. Remove the rear wheel and tire (A) from the rear hub.

    Tightening torque: 107.9–128 N·m

  3. Remove the rear drive shaft. (Refer to Rear Drive Shaft Assembly - "Rear Drive Shaft")
  4. Remove the propeller shaft. (Refer to Propeller Shaft Assembly - "Propeller Shaft")
  5. Disconnect the pressure sensor connector (A).
  6. Disconnect the oil hydraulic motor connector (A).
  7. Support the differential assembly with a jack.
  8. Loosen the differential mounting bolts, then remove the differential assembly (A).
  9. Remove the differential case (B) from the coupling (A).
  10. Remove the differential carrier bracket (A).

Disassembly

[Differential Case Assembly]
  1. Drain the oil by removing the drain plug (A) before removing the rear differential carrier.
  2. Using SST (09501-C9230), securely hold the differential assembly.
  3. Loosen the cover bolts and remove the cover (A).
  4. Remove the carrier assembly (A).
  5. Using SST (09501-C9200), remove the front/rear bearing.
  6. Loosen the seal bolts, then remove the gear carrier (A) and ring gear (B).
  7. Using SST (09501-C9230), remove the drive pinion lock nut (A).
  8. Using a press, remove the drive pinion (A).
  9. Remove the shim (A) from the drive pinion assembly.
  10. Remove the oil seal (A).
  11. Using SST (09501-C9140), remove the upper/lower race.
  12. Using a press and SST (09501-C9120, 09452-2E000), remove the gear bearing from the drive pinion.
  13. Remove the adjusting bearing (A) from the drive pinion.
  14. Using a screwdriver (-), remove the front/rear bearing race and shim.
  15. Remove the differential case side oil seal (A).
[Drive Pinion Gear Assembly]

Installation

  1. Install the inner bearing adjusting shim (A) onto the drive pinion.
  2. Using a press and SST (09501-C9130), install the gear bearing.
  3. Install the spacer (A) onto the drive pinion assembly.
  4. Using SST (09501-C9150), install the upper outer race and bearing (A).
  5. Using SST (09501-C9150), install the lower outer race and bearing (A).
  6. Install the upper bearing (A).
  7. Using a press, install the drive pinion assembly (A).
  8. Using SST (09501-C9100, 09231-H1100), install the pinion seal.
  9. Using SST (09501-C9230), install the pinion lock nut (A).
  10. Measure the pinion preload.

    Pinion preload: (9.2 - 18.3 kgf.m)

  11. Using SST (09231-H1100, 09501-C9190), install the side oil seal.
  12. Install the side bearing race.
  13. Install the differential case (A) and ring gear (B).
  14. Using SST (09501-C9210) and a press, install the front/rear bearing.
  15. Install the differential case (A).
  16. Install the side cover.

    Sealant: L5702

  17. Measure the differential backlash.

    Differential backlash: 0.01 to 0.06 mm

  18. Measure the total preload. Standard: Ring gear +0.24 - 0.8 N·m
  19. Install the drain plug (A).

    Tightening Torque: 49.0–69 N·m

[Differential Case Assembly]

Inspection

  1. After cleaning, inspect the parts for damage or wear. Follow the method below if any is found.
    Item Identify
    Gear Set (Drive Pinion and Ring Gear) Replace the gear set with a new one if the gear teeth are damaged (cracks/pits/dents).
    Bearing Replace the bearing with a new one if the roller or race is damaged (cracks/pits/dents).
    Seal Replace the seal with a new one whenever the differential is disassembled.
    Differential Case Replace the carrier with a new one if the inner bearing bore is damaged (cracks/pits/dents) or if a crack is found inside or outside.
    Companion Flange Replace the pinion seal with a new one if the contact surface is damaged (cracks/pits/dents).
    Open Type Differential Gear Set
    (Differential Side Gear and Differential Pinion Gear)    		 Replace the gear set with a new one if the gear tooth or tooth surface is damaged (cracks/pits/dents).
    Differential Washer
    (Differential Side Gear Washer and Differential Pinion Gear Washer)    		 Replace the washer with a new one if the washer surface is damaged (cracks/pits/dents).

Installation

  1. Install the differential carrier bracket (A).
  2. Install the differential carrier (B) and the coupling (A).

    Tightening torque: 56.9–65 N·m

  3. Install the differential carrier and coupling assembly (A).

    Tightening torque: 68.6–88 N·m

  4. Fill with new oil through the filler hole (A). Oil type: Hypoid transmission oil MS517-15 GT 75W/90 (GL-5) (SHELL HD AXLE OIL 75W90, or equivalent SK HK G-5 75W90). Oil capacity (liters): 0.50 ± 0.1 L. Tightening torque: 39.2–59 N·m
  5. Connect the connector of the oil hydraulic motor (A).
  6. Connect the connector of the pressure sensor (A).
  7. Install the propeller shaft. (Refer to Propeller Shaft Assembly – "Propeller Shaft")
  8. Install the rear propeller shaft. (Refer to Rear Drive Shaft Assembly – "Rear Drive Shaft")
  9. Install the rear wheel and tire (A) on the rear hub.

    Tightening torque: 107.9–128 N·m

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