Hyundai Genesis (DH): Differential Carrier Assembly / Front Differential Assembly(AWD) Repair procedures

Hyundai Genesis (DH) 2013-2016 Service Manual / Driveshaft and axle / Differential Carrier Assembly / Front Differential Assembly(AWD) Repair procedures

Removal
1.
Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported
2.
Remove the front wheel and tire (A) from the front hub.

   
Be careful not to damage the hub bolts when removing the front wheel and tire.
3.
Remove the under cover (A) & (B).

4.
Remove the Sub frame.
(Refer to Suspension System - "Sub Frame")
   
Using SST " Engine support fixture", support the Engine.

5.
Remove the front propeller shaft by loosening bolts. [Both side]
Tightening torque:
49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)

6.
Remove the steering gear box.
(Refer to Steering System - "Motor Driven Power Steering")
7.
Remove the front driveshaft.
(Refer to Driveshaft & Axle - "Front Driveshaft Assembly")
8.
Remove the engine mount (A).

9.
Remove the front differential assembly.
Tightening torque :
58.8 ~ 63.7 N.m (6.0 ~ 6.5 kgf.m, 43.4 ~ 47.0 lb-ft)

10.
Install in the reverse order of removal.
Disassembly
[Differential Case Assembly]
1.
Drain oil by removing the drain plug (A).

   
Use a new washer (A) when reinstalling the drain plug.
2.
Place the front differential assembly in the SST (09474-4E400).

3.
Remove the side oil seal (A) using a screwdriver.

4.
Loosen the bolts to remove the cover (B) from the differential carrier.

5.
Remove the spacer (A), side bearing race (B) using a hammer and chisel.

6.
Separate the differential case assembly from the differential carrier.

7.
Remove the oil seal (A) from the differential carrier.

8.
Using the SST (09452-2W300), remove the spacer & bearing race from the differential carrier.

9.
Using the SST (09474-4E200), remove the side bearing.

   
Use a new bearing when reinstalling.
A spray lubricant can be used to facilitate the removal of the bearings.
10.
Loosen the bolts and then remove the differential case (A) and ring gear (B).
   
Put the match marks on the gear carrier and the ring gear.

[Pinion drive gear assembly]
1.
Remove the pinion cage.
(1)
Using the SST (09474-4E400), place the front differential carrier.
(2)
Loosen the lock nut and remove the companion flange (A).

2.
Loosen the bolts and remove the pinion cage.
Tightening torque :
34.3 ~ 37.3 N.m (3.5 ~ 3.8 kgf.m, 25.3 ~ 27.5 lb-ft)

3.
Remove the pinion drive gear assembly using a press.

4.
Remove the pinion oil seal (A) & pinion front bearing from the pinion cage by a screwdriver.

5.
Using a hammer and chisel, remove the pinion front bearing race (A).

6.
Separate the pinion bearing spacer.

7.
Using a press, remove the pinion rear bearing.

Inspection
1.
After clearing, check for damage parts or abrasion. Follow the method below, if any are noticed.
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/outside.
Companion flange
The pinion oil seal must be replaced with a new one if the contact surface is damaged (crack/pits/dents).
Open type
Diff gear set
(Diff side gear & diff pinion gear)
The gear set must be replaced with a new one if the gear tooth or tooth surface is damaged (crack/pits/dents).
Diff washer
(Diff side gear washer & diff pinion gear washer)
The washer must be replaced with a new one if the washer surface is damaged (crack/pits/dents).

Reassembly
   

    Components Location 1. Front propeller shaft2. Transfer case3.Front differential assembly Components 1. Pinion lock nut 2. Companion flange 3.

    Component 1. Rear differential carrier assembly Component [With Lambda Engine] 1. Pinion lock nut 2. Companion flange 3. Pinion oil seal 4.

    Other information:

    Hyundai Genesis (DH) 2013-2016 Service Manual: PGS Unit (Back & Blinde Unit) Repair procedures

    Removal 1. Disconnect the negative (-) battery terminal. 2. Remove the glove box housing (A). (Refer to Body - "Glove Box") 3. Remove the PGS unit (A) after loosening the nuts. Installation 1. Install the PGS unit. 2. Install the glove box housing.

    Hyundai Genesis (DH) 2013-2016 Service Manual: Compressor Repair procedures

    Removal 1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off. 2. Disconnect the negative (-) battery terminal. 3. Remove the engine room cover.

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