Differential — disassembly and assembly (Hyundai Sonata Y3)

Disassembly

1. Clamp the differential housing in a vice.

2. Remove the bolts holding the differential drive gear and remove it from the housing.

3. Remove the ball bearing using a special tool (09433-21000; 09532-11301)

4. Knock out the locking pin from hole A.

5. Knock out the satellite axle.

6. Remove both the pinions and washers, axle gears and spacer rings.

6. Remove both the pinions and washers, axle gears and spacer rings.

Assembly

1. Install the spacer ring on the rear side of the axle gear and then install the gear into the differential housing.

Warning:

1. When installing a new axle gear, use a spacer ring of medium thickness (0.93-1.00 mm).

2. Do not reuse the locking pin.

3. The head of the locking pin must be recessed below the surface of the differential housing flange.

2. Place a washer on the back of each satellite and set both pinions to the required positions by engaging them with the axle gears by turning.

3. Install the satellite axis.

4. Measure the clearance between the axle gears and the satellites.

Standard size: 0.025-0.150 mm

5. If the clearance is outside the specified limits, disassemble and install the proper spacer ring, then reassemble and remeasure.

Caution: Adjust the clearance for both axle gears to the same value.

6. Align the pin hole in the pinion shaft with the pin hole in the differential housing and install the pin.

Warning:

1. Do not reuse the locking pin.

2. The head of the locking pin must be recessed and located below the surface of the differential housing flange.

(The material is republished from the web portal: www.HyundaiBook.ru)

2. The head of the locking pin must be recessed and located below the surface…

7. Install the tapered roller bearings on both sides of the differential housing using the special tool (09455-21100).

Caution: When installing bearings with a press fit, apply pressure only to the inner race.

8. Apply the recommended sealant to the bolt threads and tighten them in the order shown in the illustration to the specified torque with the differential housing clamped in a vice.