Hyundai Tucson Quiz
Drive Shaft and Axle

Repair Procedures

In this manual: Drive Shaft and Axle
General Information — 17Engine Mechanical System — 51Engine Electrical System — 26Emission Control System — 23Engine/Fuel Control System — 44Clutch System — 12MANUAL TRANSMISSION SYSTEM — 12AUTOMATIC TRANSMISSION SYSTEM — 42Four-Wheel Drive (4WD) System — 14Drive Shaft and Axle — 22Suspension System — 30Steering System — 16Restraint — 21Braking System — 47Body Work (Interior and Exterior) — 145Body Electrical System — 162Heating, Ventilation and Air Conditioning — 39
48steps
~308min
5/5difficulty
4special tools
04080120160200107.980N·mlb·ft
Tightening torque found on this page
Done 0 of 48

DEPOSIT

  1. Raise the vehicle and make sure it is securely supported.
  2. Remove the front wheel and tire assembly (A) from the hub.

    Tightening torque: 88.3 ~ 108 N·m

  3. Loosen the drain plug (A) and drain the differential gear oil.

    Tightening torque: 49.0 ~ 69 N·m

  4. Remove the rear drive shaft. (Refer to Drive Shaft "Propeller Shaft" – Rear.)
  5. Remove the drive shaft. (Refer to Drive Shaft Assembly "Propeller Shaft".)
  6. Disconnect the pressure switch connector and the oil hydraulic motor connector.
  7. Remove the rear differential (B) after loosening the mounting bolts (A-4EA) and set a jack.

    Tightening torque: 68.6 ~ 88 N·m

  8. After loosening the bolt, remove the differential carrier (B) and coupling (A).

    Tightening torque: 56.9 ~ 65 N·m

  9. Remove the axle head bracket after loosening the bolts.
  10. To install, perform the removal procedure in reverse order.
  11. Fill with differential gear oil. Recommended lubricants: MC517-15GT 75W/90 (GL-5) (SHELL HD AXLE OIL 75W/90 or equivalent SK HK G-5 75W/90). Oil quantity (l): 0.58 ± 0.05
  12. Check the rear toe alignment. (See Suspension System — Wheel Alignment)

DISASSEMBLY

Disassembly of Differential Case

  1. Using SST (09530-3T300), securely hold the differential and loosen the pinion shaft lock (A).
  2. Loosen the cap bolts, then remove the cap.
  3. Loosen the bolts and remove the bearing cap (A).
  4. Remove the differential case.
  5. Using a screwdriver, remove the left and right seals (A).
  6. Using SST (09501-C9200) and a puller, remove the front and rear bearings.
  7. Loosen the lock bolts, then remove the pinion cage (A) and ring gear (B).

Pinion Gear Pinion Gear Pinion Gear

  1. When using SST, use the pinion lock nut.
  2. Using a press, separate the pinion gear.
  3. Remove the pinion oil seal (A) and the pinion front bearing (B).
  4. Using a hammer and chisel, remove the pinion front bearing outer race.
  5. Remove the pinion bearing spacer (A).
  6. Using SST (09530-2W200), press the drive pinion, then remove the pinion rear bearing.
  7. To do this, remove the pinion front bearing (A) and the inner bearing adjusting shim (B).

Inspection

  1. Make sure the parts are not damaged or worn. Follow the method below, if applicable.
    Item Identify
    Planetary Gear Set (Drive Pinion and Driven Pinion) The planetary gear must be replaced with a new one if the gear teeth are damaged (cracks, chipped teeth).
    BEARING The bearing must be replaced with a new one if the rollers or race are damaged (cracks, chipped surfaces).
    Oil seal The removed oil seal must be replaced with a new one.
    Differential Case The carrier must be replaced with a new one if the inner part of the bearing seat is damaged (cracks, chipped surfaces), or if a crack is present inside or on the outside.
    Drive Pinion Shaft The pinion oil seal must be replaced with a new one if the contact surface is damaged (cracks, chipped surfaces).
    Open Type Differential Gear Backlash
    (Differential Side Gear and Differential Pinion Gear)    		 The planetary gear must be replaced with a new one if the gear teeth or tooth surfaces are damaged (cracks, chipped teeth).
    Differential Washer
    (Differential Side Gear Washer and Differential Pinion Gear Washer)    		 The washer must be replaced with a new one if its surface is damaged (cracks, chipped surfaces).

Installation

[Axle Housing]

  1. Using SST, install the pinion front bearing outer race.
  2. Using SST, install the pinion rear bearing outer race.
  3. Install in order the pinion front bearing (A) and the inner bearing adjustment (B).
  4. Press the rear pinion bearing (B) in using a hollow tube.
  5. Install the pinion bearing spacer (A).
  6. Install the front pinion bearing and pinion oil seal.
  7. Using a press, install the drive pinion onto the axle head.
  8. Using SST, install the side oil seal.
  9. Using SST, install the pinion lock nut.

    Tightening torque: 186.3 ~ 441 N·m (19.0 ~ 45.0 kgf·m, 137.4 ~ 325.5 ft·lbf)

  10. Measure the gear operation.

    Standard value: 0.9 ~ 1.8 N·m

[Differential Case]

  1. Install the drive pinion carrier and ring gear.
  2. Using SST (09543-02100) and a press, install the side bearing.
  3. Install the differential case onto the axle housing.
  4. Install the bearing caps (A).

    Tightening torque: 44.1 ~ 54 N·m

  5. Measure the gear backlash.

    Standard value: 0.07 ~ 0.15 mm (0.003 ~ 0.006 in.)

  6. Measure the total preload. Total preload: Pinion bearing preload (9.2 ~ 18.3 kgf·cm) + (2.5 ~ 8.5 kgf·cm)
  7. Apply red paint to the ring gear teeth and rotate the gear to check the tooth contact.
    Tooth contact Contact condition Solution
    Standard contact
    1. Heel Contact
    		Increase the thickness of the pinion height adjusting shim and move the drive pinion closer to the ring gear.
    Move the ring gear farther from the drive pinion to also adjust the backlash.
    2. Face Contact
    3. Toe contact
    		Decrease the thickness of the pinion height adjusting shim and move the drive pinion farther from the ring gear.
    Move the ring gear closer to the drive pinion to also adjust the backlash.
    4. Heel contact

  8. Apply sealant (B) to the surface of the rear cover.

    Sealant: Equivalent to LT#5060

  9. Install the rear differential cover (A).

    Tightening torque: 78.5 - 88 N·m

  10. Install the drain plug (A).

    Tightening torque: 49.0 ~ 69 N·m

  11. Fill with gear oil. Recommended lubricant: MC517-15GT 75W/90 (GL-5) (SHELL HD AXLE OIL 75W/90 or equivalent SK HK G-5 75W/90). Oil quantity (L): 0.58 ± 0.05
  12. Install the stud cap.

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