Manual Transaxle System: Differential: Reassembly

Install the spacer on the back of the side gear and then install the gear in the differential case.
CAUTION: When installing a new side gear, use a spacer of medium thickness [0.93~1.00 mm (0.0366~0.0394 in.)].

Fig 1: Installing Side Gear Into Differential Case
Courtesy of KIA MOTORS AMERICA, INC.
Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears by turning them.
Insert the pinion shaft.

Fig 2: Installing Pinion Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Measure the backlash between the side gears and pinions.
Standard value: 0.025~0.150 mm (0.001~0.006 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.

Fig 3: Checking Backlash
Courtesy of KIA MOTORS AMERICA, INC.
Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.
CAUTION:
- Do not reuse the lock pin.
- The lock pin head must be sunk below the flange surface of the differential case.
  
  Fig 4: Installing Lock Pin
  Courtesy of KIA MOTORS AMERICA, INC.
Install the taper roller bearings on both sides of the differential case using the special tool (09455-21100).
CAUTION: When press-fitting the bearing, press on the inner race only.

Fig 5: Installing Tapered Roller Bearings Onto Differential Case
Courtesy of KIA MOTORS AMERICA, INC.
Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the illustration.
Specified sealant: BM Stud Locking No. 2471.

Tightening torque

Differential drive gear bolt: 130~140 Nm (1300~1400 kg.cm, 94~101 lb. ft)

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

Fig 6: Differential Drive Gear Bolt Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.