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 [0.0366-0.0394 in (0.93-1.00 mm)].

Fig 1: Installing Spacer On Back Of Side Gear
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: Inserting Pinion Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Measure the backlash between the side gears and pinions.
Standard value :

0.001-0.006in (0.025-0.150mm)
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 Between Side Gears And Pinions
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: Inserting Lock Pin
  Courtesy of KIA MOTORS AMERICA, INC.
Install the taper roller bearings on both sides of the differential case.
CAUTION: When press-fitting the bearing, press on the inner race only.

Fig 5: Identifying Taper Roller Bearings On 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.

TORQUE

Differential drive gear bolt:

130-140N.m (1300-1400kg.cm, 94-101lb-ft)

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

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