SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2000
GROUP
Transaxle/Transmission Manual Transaxle System
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COMPONENTS 
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DISASSEMBLY 
  1. Clamp the differential case in a vise.

  1. Remove the differential drive gear retaining bolts and remove the differential drive gear from the case.

  1. Remove the taper roller bearing using the special tool (09433-21000).

    CAUTION
    Do not reuse the bearing removed from the shaft,
  1. Drive out the lock pin from the hole A using a punch.

  1. Drive out the pinion shaft.

  1. Remove the pinion gears, washers, side gears and spacers.

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REASSEMBLY 
  1. Install the spacer on the back of the side gear and then install the gear in the differential case.

    CAUTION
    When installing a new side gear, use a spacer of medium thickness. [0.93 - 1.00 mm (0.0366-0.0394 in.)]
  1. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears by turning them.

  1. Inset the pinion shaft.

  1. Measure the backlash between the side gears and pinions.

    MEASUREMENT SPECIFICATION
    Backlash between the side gears and pinions 0.025-0.150 mm ( 0.001-0.006 in )
  1. If the backlash is out of specification, disassemble and install the correct spacer, reassemble and remeasure.

    CAUTION
    Adjust the backlash of both side gears to the same specification.
  1. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.

    CAUTION
    1. Do not reuse the lock pin.
    2. The lock pin head must be sunk below the flange surface of the differential case.
  1. Install the taper roller bearings on both sides of the differential case using the special tool (09455-21100).

    CAUTION
    when press-fitting the bearing, press on the inner race only.
  1. Apply specified sealant to the entire threads of the bolts. Tighten to specifications using the sequence shown in the illustration. Specified sealant; BM Stud Locking No.2471.

    TORQUE SPECIFICATION
    Differential drive gear bolt 130-140 Nm ( 1300-1400 kg·cm, 94-101 lb·ft )
    CAUTION
    If a bolt is reused, remove the old sealant from the threads.