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Kia Sorento: Rear Differential Carrier Repair procedures - Differential Carrier Assembly - Driveshaft and axleKia Sorento: Rear Differential Carrier Repair procedures

Kia Sorento (MQ4, 2021-2026) Service Manual / Driveshaft and axle / Differential Carrier Assembly / Rear Differential Carrier Repair procedures

Removal
1.
Disconnect the (-) battery terminal.
2.
Remove the rear driveshaft.
(Refer to Rear Driveshaft Assembly - "Rear Driveshaft")
3.
Remove the propeller shaft.
(Refer to Propeller Shaft Assembly - "Propeller Shaft")
4.
Remove the coupling assembly.
(Refer to All Wheel Drive (AWD) System - "Direct Electro Hydraulic Actuator Coupling")
5.
Remove the drain plug (A) to drain the gear oil before removing the rear differential carrier.
Tightening torque :
49.0 - 68.6 N·m (5.0 - 7.0 kgf·m, 36.1 - 50.6 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Removal illustration

Note
When installing the drain plug (A), use a new one.
6.
Install the jack and remove the differential mounting bolts to remove the rear differential assembly (A).
Tightening torque :
68.6 - 88.2 N·m (7.0 - 9.0 kgf·m, 50.6 - 65.0 lb·ft)
[Front]

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Removal illustration

[Rear]

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Removal illustration

7.
Remove the bolts and remove the differential carrier bracket (A).
Tightening torque :
56.8 - 64.7 N·m (5.8 - 6.6 kgf·m, 41.9 - 47.7 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Removal illustration

Disassembly
Differential gear assembly.
1.
Remove the air breather (A).
Tightening torque :
9.8 - 19.6 N·m (1.0 - 2.0 kgf·m, 7.2 - 14.4 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

2.
Remove the differential carrier side cover fixing bolts.
Tightening torque :
39.2 - 49.0 N·m (4.0 - 5.0 kgf·m, 28.9 - 36.1 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

3.
Widen the gap between the side cover and the case to remove the side cover (A).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

4.
Remove the differential gear assembly (A).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

5.
Remove the bolt and remove the ring gear (A) from the gear carrier.
Tightening torque :
78.4 - 88.2 N·m (8.0 - 9.0 kgf·m, 57.8 - 65.0 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

6.
Remove the differential gear bearing (A) using SST (09501-C9200) and puller.
[Differential carrier cover side]

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

[Differential carrier side]

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Note
Do not reuse the removed bearing.
Pinion drive gear assembly.
1.
Fix the differential carrier assembly using SST (09501-C9230, 0K530-P2500, 0K501-P2232).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

2.
Remove the pinion gear lock nut using SST (09501-C9230).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Note
When istalling lock nut, use a new one.
3.
Remove the pinion drive gear assembly (A) using puller.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

4.
Remove the spacer (A) from pinion drive gear assembly.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Caution
When installing the spacer (A), make sure the spacer (A) is in the correct direction.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

5.
Install SST (09501-C9120, 09452-2E000) and remove the bearing (A) from the pinion drive gear using a press.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Note
Do not reuse the removed bearing.
6.
Remove the pinion inner bearing adjustment shim (A) from the pinion drive gear.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Differential carrier case
1.
Remove the pinion oil seal (A) using SST (09455-32200, 09501-C9200).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Note
When installing oil seal (A), replace oil seal with a new one.
2.
Remove the outer pinion bearing (A).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Note
Do not reuse the removed bearing.
3.
Remove the inner pinion bearing race (A) using SST (09501-C9140).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Information
When using SST (09501-C9140), insert the SST into the groove.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

4.
Remove the outer pinion bearing race (A) using SST (09501-C9140).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

5.
Remove the differential carrier case side oil seal (A) using SST (0K530-P2300).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Note
When installing oil seal (A), replace oil seal with a new one.
6.
Remove the differential carrier case side cover oil seal (A) using SST (0K530-P2300).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Note
When installing oil seal (A), replace oil seal with a new one.
7.
Remove the differential carrier case side bearing race (A) and adjustment shim (B).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

8.
Remove the differential carrier case side cover bearing race (A) and adjustment shim (B).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

9.
Remove the filler gasket (A) and filler plug (B) from the differential carrier case side cover.
Tightening torque :
39.2 - 58.8 N·m (4.0 - 6.0 kgf·m, 28.9 - 43.3 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Disassembly illustration

Note
When installing the filler plug, replace the gasket (A) with a new one.
Inspection
1.
After clearing, check for damaged or worn parts and follow the methods below if applicable.
Item
 Identify
Gear set (drive pinion gear & drive gear)
 The gear set must be replaced with a new one if the gear tooth is damaged (crack/pits/dents).
Bearing
 The bearing must be replaced with a new one if the bearing roller or race is damaged (crack/pits/dents).
Oil seal
 The oil seal must be replaced with a new one if disassembled.
Differential carrier
 The carrier must be replaced with a new one if the inside of the carrier bearing is damaged (crack/pits/dents) or a crack is found inside/ouside.
Companion flange
 The pinion oil seal must be replaced with a new one if the contact surface is damaged (crack/pits/dents).

2.
Check the tooth contact pattern.
Tooth contact
 Contact state
 Solution
Standard contact

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Inspection illustration



1. Heel contact

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Inspection illustration

Increase the thickness of the pinion height adjusting shim, and position the drive pinion closer to the center of the drive gear.Also, for backlash adjustment, reposition the drive gear further from the drive pinion.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Inspection illustration

2. Face contact

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Inspection illustration

3. Toe contact

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Inspection illustration

Decrease the thickness of the pinion height adjusting shim, and position the drive pinion further from the center of the drive gear.Also, for backlash adjustment, reposition the drive gear closer to the drive pinion.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Inspection illustration

4. Flank contact

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Inspection illustration


Note
•
Tooth contact pattern is a method for judging the result of the adjustmentof drive pinion height and final drive gear backlash. The adjustment of drivepinion height and final drive gear backlash should be repeated until the toothcontact patterns are similar to the standard tooth contact pattern.
•
When you cannot obtain a correct pattern, the drive gear and drive pinionhave exceeded their limits. Both gears should be replaced as a set.
Reassembly
Pinion drive gear assembly
1.
Install the inner pinion bearing adjustment shim (A) on the pinion drive gear assembly.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

2.
Install the inner pinion bearing (A) on the pinion drive gear using SST (0K530-P2300) and press.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
Do not reuse the removed bearing.
3.
Install the spacer (A) in the pinion drive gear assembly.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Caution
When installing the spacer (A), make sure the spacer (A) is in the correct direction.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Differential gear assembly
1.
Install the ring gear (A) on the gear carrier.
Tightening torque :
78.4 - 88.2 N·m (8.0 - 9.0 kgf·m, 57.8 - 65.0 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

2.
Install the differential gear bearings (A) on both sides using SST (0K530-P2300) and press.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
Do not reuse the removed bearing.
Differential carrier case
1.
Install the drain plug packing (A) and drain plug (B) in the differential carrier.
Tightening torque :
49.0 - 68.6 N·m (5.0 - 7.0 kgf·m, 36.1 - 50.6 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
When installing the drain plug packing (A), replace it with a new one.
2.
Install the differential carrier case side cover bearing adjustment shim (A) and race (B).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
Be careful not to confuse the type of each bearing race when reassembling

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

3.
Install the differential carrier case side bearing adjustment shim (A) and race (B).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
Be careful not to confuse the type of each bearing race when reassembling

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

4.
Install the outer pinion bearing race using SST (09501-C9150).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Information
When installing the race (A) using SST, install it from the outside as follows.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

5.
Install the inner pinion bearing race (A) using SST (09501-C9150).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Information
When installing the race (A) using SST, install it from the inside as follows.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
Be careful not to confuse the type of each bearing race when reassembling

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

6.
Install outer pinion bearing (A) on pinion gear assembly.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
Do not reuse the removed bearing.
7.
Place the SST (0K530-P2200) on the pinion gear spline side and hammer the top of the SST (0K530-P2200) until the thread can engages the lock nut.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

8.
Pre-tighten the pinion lock nut (A) to the thread on the side of the pinion gear spline.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
When you installing lock nut (A), replace lock nut with a new one.
9.
Hold the differential carrier assembly using SST (09501-C9231, 0K530-P2500, 0K501-P2232).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

10.
Tighten the pinion gear lock nut (A) using SST (09501-C9231) to press the outer bearing.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

11.
Press the pinion oil seal (A) using SST (0K530-P2100, 09231-H1100).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
•
When pressing the seal (A), make sure that the gap between the differential carrier case and the pinion oil seal is 0 - 0.5 mm.
•
When installing oil seal (A), replace oil seal with a new one.
12.
Install the differential gear assembly (A) in the differential carrier case.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

13.
Install the differential carrier case side cover (A).
Tightening torque :
39.2 - 49.0 N·m (4.0 - 5.0 kgf·m, 28.9 - 36.1 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

14.
Install SST (0K530-P2400) on the pinion drive gear spline side and set the dial gauge on the case.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
•
After setting the dial gauge on the gear to be measured, adjust the dial gauge to zero.
•
Secure the dial gauge to the housing to prevent it from moving or shaking.
•
When measuring, be careful that the dial gauge or jig does not interfere with the gear.
•
Make the measuring surface part and dial gauge at right angles.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

15.
After moving the SST (0K530-P2400) left and right, read the dial gauge and measure the backlash.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Information
•
After reading dial gauge, adjust backlash to be within the standard value range below.
Gear Backlash (mm)
 C/FLANGE
0.07
 0.16
0.08
 0.19
0.09
 0.21
0.10
 0.23
0.11
 0.25
0.12
 0.28
0.13
 0.30
0.14
 0.32
0.15
 0.35

•
If the measured value deviates from the standard value specification, bearing adjustment shim (A) on the differential carrier case side.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Division
 Solution
Out of upper limit
 Thiner
Out of lower limit
 Thicker

16.
Measure the total preload.
Tightening torque :
114.7 - 262.8 N·m (11.7 - 26.8 kgf·m, 84.6 - 193.8 lb·ft)
Information
•
Maintain constant rotation while measuring (about 60 RPM).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

•
If the measured value deviates from the standard value specification, bearing adjustment shim (A) on the differential carrier case side.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Division
 Shim adjustment
Out of upper limit
 Thiner
Out of lower limit
 Thicker

17.
Remove the bolt and remove the differential carrier case side cover (A).
Tightening torque :
39.2 - 49.0 N·m (4.0 - 5.0 kgf·m, 28.9 - 36.1 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

18.
Apply the sealant on the adhesive side between differential carrier case and side cover.

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Caution
•
Remove the used sealant before applying the sealant.
•
Apply evenly 2 - 3mm along the surface of the case.
19.
Install the differential case side cover (A).
Tightening torque :
39.2 - 49.0 N·m (4.0 - 5.0 kgf·m, 28.9 - 36.1 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

20.
Install the oil seal on both sides of the differential carrier case using SST (09501-C9190, 09231-H1100).

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Note
Do not reuse the removed oil seal.
21.
Install the air breather (A).
Tightening torque :
9.8 - 19.6 N·m (1.0 - 2.0 kgf·m, 7.2 - 14.4 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Reassembly illustration

Installation
1.
Install the differential carrier bracket (A).
Tightening torque :
56.9 - 64.7 N·m (5.8 - 6.6 kgf·m, 42.0 - 47.7 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Installation illustration

2.
Install the jack and intall the differential carrier assembly (A).
Tightening torque :
68.6 - 88.3 N·m (7.0 - 9.0 kgf·m , 50.6 - 65.1 lb·ft)
[Front]

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Installation illustration

[Rear]

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Installation illustration

3.
Add new gear oil through filler plug hole (A).
Hypoid gear oil API GL-5, SAE 75W/85
(SK HCT-5 gear oil 75w/85 or equivalent oil)
0.58±0.05
Tightening torque :
39.2 - 58.8 N·m (4.0 - 6.0 kgf·m, 28.9 - 43.4 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Installation illustration

4.
Install the filler plug (A) and filler gasket (B).
Tightening torque :
39.2 - 58.8 N·m (4.0 - 6.0 kgf·m, 28.9 - 43.4 lb·ft)

Driveshaft and axle — Differential Carrier Assembly / Rear Differential Carrier / Repair procedures / Installation illustration

Note
When installing the filler plug, replace the gasket (B) with a new one.
5.
Install the coupling assembly.
(Refer to All Wheel Drive (AWD) System - "Direct Electro Hydraulic Actuator Coupling")
6.
Install the propeller shaft.
(Refer to Propeller Shaft Assembly - "Propeller Shaft")
7.
Install the rear driveshaft.
(Refer to Rear Driveshaft Assembly - "Rear Drive Shaft")
8.
Install the rear wheel and tire.
(Refer to Suspension System - "Wheel")
9.
Connect the ( - ) battery terminal.
10.
Check the rear alignment.
(Refer to Suspension System - "Alignment")
Rear Differential Carrier Components and Components Location
Components 1. Rear differential carrier assembly2. Differential carrier bracket 3. Coupling assembly Components Locati...
Suspension System
...
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