Hyundai Tucson LM Quiz
Drive Shaft and Axle

Rear Differential Carrier Repair Procedures

In this manual: Drive Shaft and Axle
General Information — 1Engine Mechanical System — 44Engine Electrical System — 45Emission Control System — 24Engine Control System/Fuel System — 93Clutch System — 13Manual Transmission — 18Automatic Transmission — 87Four-Wheel Drive (4WD) System — 26Drive Shaft and Axle — 29Suspension System — 35Steering — 20Restraints — 47Brake System — 36Body (Interior and Exterior) — 53Body Electrical System — 202Heating, Ventilation, and Air Conditioning — 58
55steps
~370min
5/5difficulty
8special tools
030609012015088.365N·mlb·ft
Tightening torque found on this page
Done 0 of 55

Replacement

  1. Drain the differential gear oil.
  2. Remove the rear drive shaft.
  3. Remove the propeller shaft.
  4. Disconnect the coupling control connector (A).
  5. Support the differential assembly (A) with a jack (B).

    Tightening torque: 68.6 - 88 N·m N·m

  6. Then loosen the cover bolt and remove the differential cover (A).

    Tightening torque: 39.2 ~ 49 N·m

  7. Install in the reverse order of removal.

Disassembly

Disassembly of Rear Differential Carrier
  1. Drain the oil by removing the drain plug (A) and the filler plug (B) before disassembling the rear differential carrier.
  2. Using SST (09530-3T300), hold the differential assembly securely.
  3. Remove the breather plug (A).
  4. Loosen the cover bolts (A-8ea) and remove the cover (B).
  5. Loosen the bolts (A-4ea) and remove the bearing cap (B).
  6. Remove the carrier assembly (A).
  7. Mark the left and right side bearing outer races as shown below when removing the differential assembly to distinguish the sides.
  8. Using a screwdriver, remove the left and right seals (A).
  9. Loosen the lock bolts, then remove the drive pinion carrier (A) and ring gear (B).
    • Make alignment marks on the carrier and ring gear.
  10. Using SST (09530-3T200), remove the front and rear bearings (A).
  11. Mark the left and right bearings as shown below when removing the bearing to distinguish the sides.
  12. Using SST (09530-3T300), secure the differential case assembly.
  13. Secure SST (09530-2W300) to the lock nut.
  14. Secure the flange holder (A) with SST (09530-2W300).
  15. Insert SST (09530-2W400) into the hex hole and remove the lock nut (A).
  16. Using a screwdriver, remove the pinion seal (A).
  17. Press on the drive pinion and remove the pinion front bearing (A).
  18. Using a hammer and chisel, remove the pinion bearing outer race (A).
  19. Using SST (09527-4A000), press on the drive pinion, then remove the pinion bearing spacer (A), front bearing (B), and inner bearing adjusting shims (C) in order.
Disassembly of Differential Carrier Assembly: Disassemble the differential carrier assembly

Installation

Pinion Height Adjustment: Adjust the pinion height in the following order.
  1. The following special tools are used to measure gear height.
  2. The lock nut of the special service tool (A), the oil seal of the gear (B), the gear front bearing (C), the inner bearing (D) and the support housing of the special service tool (E) are installed as follows. Lock nut (A) tightening torque: 88.3 ~ 137 N·m
  3. Place the main body (A) on the differential case (B).
  4. The bearing cap (B) is installed on the main body (A).

    Tightening torque: 54.0 ~ 64 N·m

  5. Using a feeler gauge, measure the clearance between the main housing (A) and the bearing cap (B). Then select the inner bearing adjustment shim.
  6. Install the selected inner bearing adjusting shim (A).
    Inner Bearing Adjusting Shim
    Part No. Thickness inch
    53040-3C138 1,38 0,054
    53040-3C141 1,41 0,055
    53040-3C144 1,44 0,057
    53040-3C147 1,47 0,058
    53040-3C150 1,50 0,059
    53040-3C153 1,53 0,06
    53040-3C156 1,56 0,061
    53040-3C159 1,59 0,063
    53040-3C162 1,62 0,064
    53040-3C165 1,65 0,065
    53040-3C168 1,68 0,066
    53040-3C171 1,71 0,067
    53040-3C174 1,74 0,068
    53040-3C177 1,77 0,067
  7. Using SST (09530-3T100), install the outer race of the gear inner bearing (A).
  8. Using SST (09530-3T100), install the outer race of the gear outer bearing.
  9. Using a round pipe (A), press in the rear pinion bearing (B).
  10. Install the pinion bearing spacer (B) onto the drive pinion (A).
  11. Using a round pipe (A), press in the front bearing (B).
  12. Install the pinion oil seal using SST (09530-3T600).
  13. Using SST (09530-3T300), tighten the gear lock nut (A).

    Tightening torque: 186.33 ~ 441 N·m

  14. Measure the preload.

    Standard: 92.22 ~ 179 N·m (9.2 ~ 18.3 kgf.m, 66.54 ~ 132.36 ft-lbf)
    • Maintain a constant rotation speed (60 rpm).
Assembly of Rear Differential CarrierAssembly of Differential Carrier Assembly
  1. Using SST (09453-3B200), install the front/rear bearing (A).
  2. Install the drive pinion carrier and ring gear.

    Tightening torque: 137.3 ~ 157 N·m (14.0 ~ 16.0 kgf.m, 101.3 ~ 115.7 ft-lbf)

  3. Install the left and right side bearing outer races (A) onto the drive pinion carrier.
  4. Hold the outer races (A) of the left and right side bearings with both hands and install them onto the differential carrier.
  5. Insert the left and right differential adjusting shims between the differential bearing and the support. Then install the bearing cap (A) with the marks aligned.

    Tightening Torque: 53.9 ~ 64 N·m

  6. Adjust the adjusting shim and confirm the backlash specification.

    Standard: 0.10 ~ 0.15 mm (0.004 ~ 0.006 in.)
    • The differential shim thickness must be adjusted if the rear wheel is small.
    • Decrease the thickness of the left differential shim and increase the thickness of the right differential shim by the same amount that the left side was decreased.
  7. Adjust the runout of the ring gear assembly.

    Standard: 0 ~ 0.05 mm (0 ~ 0.002 in.)

  8. Measure the backlash. Standard: Ring gear backlash: 0.25 ~ 0.8 N·m
  9. Apply sealant (A) to the rear cover surface.

    Sealant: MP 721-40
    • Remove any remaining sealant before applying. Evenly apply sealant with a bead of 2~3 mm along the rear surface of the cover.
  10. Install the rear differential cover (A).

    Tightening torque: 39.2 ~ 49 N·m

  11. Install the drain plug (A) and the filler plug (B). Filler plug: 39.2 ~ 59 N·m Drain plug: 49.0 ~ 69 N·m
  12. Using SST (09530-3T000), install the left and right oil seals.
  13. Install the rear differential assembly on the vehicle and fill with oil. Oil type: Hypoid gear oil, MS 517-15GT (SAE 75W/90, API GL-5, SHELL SPIRAX). Oil capacity (L): 1.4 ± 0.1 L

Inspection

  1. After cleaning, inspect the parts for damage or wear. If any is found, follow the method below.
    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 support bearing is damaged inside (cracks/pits/dents) or a crack is found inside/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 teeth or tooth surfaces are damaged (cracks, pitting, or dents).
    Differential Washer
    (Differential Side Gear Washer and Differential Pinion Gear Washer)    		 Replace the washer with a new one if its surface is damaged (cracks/pits/dents).
    LSD type Limited slip differential assembly Replace the limited slip differential assembly with a new one if a crack is found on the outside.
  2. Check the gear tooth contact pattern.
    Tooth Contact Contact Condition Solution
    Standard Contact
    1. Heel contact
    		Increase the thickness of the pinion height adjusting shim to move the pinion closer to the ring gear.
    To adjust the backlash, move the ring gear away from the pinion.
    2. Face Contact
    3. Toe Contact
    		Decrease the thickness of the pinion height adjusting shim to move the drive pinion farther from the ring gear.
    Also, to adjust the backlash, move the ring gear closer to the drive pinion.
    4. Flank Contact

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