Tucson 2006-2008

Pinion Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the propeller shaft.
  4.  
  5. Drain the transfer oil through drain plug hole.
  6.  
  7. Remove the 7 pinion assembly mounting bolts (B) and then remove the pinion assembly (A).

    Click image to see an enlarged view

    Fig. Remove the 7 pinion assembly mounting bolts (B) and then remove the pinion assembly (A)

  8.  
  9. Remove the O-ring (A) from the pinion shaft and case assembly.

    Click image to see an enlarged view

    Fig. Remove the O-ring (A) from the pinion shaft and case assembly

  10.  
  11. Remove the spacer (A).

    Click image to see an enlarged view

    Fig. Remove the spacer (A)

  12.  
  13. Remove the HEX lock nut (A).

    Click image to see an enlarged view

    Fig. Remove the HEX lock nut (A)

  14.  
  15. Remove the rear flange assembly (A).

    Click image to see an enlarged view

    Fig. Remove the rear flange assembly (A)

  16.  
  17. Using the SST(09455-32200), remove the pinion oil seal (A) from the pinion case.

    Click image to see an enlarged view

    Fig. Using the SST(09455-32200), remove the pinion oil seal (A) from the pinion case

  18.  

To install:

  1. Install the oil seal and the rear flange assembly.
  2.  
  3. Tighten down the hex lock nut until there is an axial clearance B of 0.0099-0.0296 inch (0.25mm-0.75mm) between pinion and pinion case.
    1. Measurement of B :

      Apply an additional 200N tension load (F1) to the pinion head according to arrangement Y. Rotate the pinion 10 times and measure dimension C
       
      Apply a 200N load (F2) to the rear flange. Rotate the pinion 10 times and measure dimension D
       
      B = C minus D
       

    2.  
    3. Measure dimension Ev.
      NOTE
      To achieve the target preload torque, it is permissible to gradually increase the tightening torque. If the permissible preload torque of 19 inch lbs. (2.1 Nm) is exceeded, it is not allowed to loosen the Hex lock nut. Disassemble the whole pinion assembly. Replace the collapsible spacer and repeat the mounting procedure.



      Tighten HEX lock nut
       
      Measure the drag torque of the pinion assembly. Target is 16-19 inch lbs. (1.8-2.1 Nm)
       

    4.  
    5. Measure dimension En.
      WARNING
      The collapsible spacer must be replaced during reassembly. Permanent deformation is caused by the tightening procedure.



      Check preload. A preload torque of 16-19 inch lbs. (1.8-2.1 Nm) corresponds to a bearing preload of 0.0047-0.0063 inch (0.12-0.16mm)
       
      Ev minus En minus B = 0.0047-0.0063 inch (0.12-0.16mm)
       

    6.  

  4.  
  5. Assemble the O-ring and select the proper spacer for reassembling the transfer case.

    Click image to see an enlarged view

    Fig. Install the oil seal and the rear flange assembly. Tighten down the hex lock nut until there is an axial clearance B of 0.0099-0.0296 inch (0.25mm-0.75mm) between pinion and pinion case

  6.  
  7. Install the 7 pinion assembly mounting bolts. Tighten the bolts to: 15-22 ft. lbs. (37-40 Nm).
  8.  
  9. Install the pinion assembly.
  10.  
  11. Install the propeller shaft to the transfer case. Tighten to: 36-51 ft. lbs. (50-70 Nm).
  12.  
  13. Fill the transfer case with the proper amount and type of oil.
  14.  
  15. Check for leaks.
  16.  

 
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