Drivetrain - Revised Rear Differential Carrier Removal
GROUP CHASSISNUMBER 023
MODEL SORENTO (BL) ALL
DATE MARCH 2010
SUBJECT
IMPROVEMENT OF REAR DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT PROCEDURE
This bulletin provides an improved rear differential carrier assembly replacement procedure for better serviceability for Sorento (BL) vehicles built from March 1, 2002 to April 21, 2008. The previous procedure required the removal of the parking brake and the parking brake cable before rear axle shaft removal. In the improved service procedure, these unnecessary steps have been eliminated making the rear differential assembly replacement procedure more efficient. Please refer to information below for updated service procedure during rear differential carrier assembly replacement.
NOTICE
If metal shavings are present after the differential carrier is removed then both axles will need to be removed to properly clean both differential housing tubes before installing the new differential carrier assembly.
Service Procedure
1. Using a hoist, lift up the vehicle and remove both rear wheels.
2. Disconnect the parking brake cable (A) to the right rear brake assembly from the parking brake equalizer by unfastening nut (B). Remove the left parking cable bracket mounting bolt (C).
WARNING
During reassembly make sure parking brake cable is properly adjusted to ensure proper brake operation.
3. Drain rear differential oil and proceed to Step 4 while differential oil is draining.
4. Remove the parking brake bracket bolt as shown in the first photo. Then remove the second parking brake bracket located on top of the rear of the differential carrier housing as shown in the second photo. This will provide enough slack in the parking brake cable to allow axle shafts to be partially slid outward.
5. Propeller shaft assembly removal: Remove the four (4) bolts and nuts; then remove propeller shaft assembly.
NOTICE
Mark propeller shaft and companion flange with a paint marker (indicated by arrow) before removing propeller shaft to ensure proper indexing when reinstalling propeller shaft.
6. Remove the left and right-side rear stabilizer bar brackets, and then move rear stabilizer bar assembly away from the rear differential housing.
7. Remove left and right-side rear brake calipers by removing brake caliper mounting bolts as indicated in photo.
NOTICE
Support brake calipers by using a suitable wire or hook. Do not let brake calipers hang freely.
8. Remove both rear ABS sensors (C) from rear axle housing.
9. Remove the four (4) rear axle shaft housing/ wheel bearing hub assembly nuts and slide out the rear axle shaft from the rear differential housing approximately 11 inches. Repeat this procedure for the opposite side.
10. Remove the twelve (12) rear differential carrier mounting bolts, and then remove the carrier assembly.
NOTICE
A transmission jack will simplify the removal and installation procedure of the differential carrier.
11. Use a jack and a wooden block or equivalent to slightly raise the front of the differential carrier assembly (D) to break the seal with the axle housing (E) allowing the carrier to be separated for removal. Carefully remove the rear differential carrier assembly.
NOTICE
The housing is notched to allow for ring gear clearance when removing/installing carrier assembly.
The carrier assembly must be lifted and rotated slightly during removal.
NOTICE
Before reinstalling the differential carrier; clean and apply sealer (Three Bond 1215 or equivalent) to contact surfaces of rear differential carrier assembly and the carrier housing.
12. Install components in reverse order of removal. Consult Shop Manual for tightening torque specifications.
Refill differential with correct type of gear oil, see notice below.
NOTICE
Gear Oil Specs: Hypoid Type
Conventional Differential: SAE90, API GL-5
With Limited Slip Differential: SAE85W90, API GL-5
AFFECTED PRODUCTION RANGE
PARTS INFORMATION