Replace the limited slip clutch pack in the rear differential of a 2016-2024 Hyundai Tucson 2.5L AWD to restore proper torque transfer between rear wheels.

Warnings

Tools required

Parts

• Limited slip clutch pack kit × 1 — Use OEM Hyundai clutch pack for rear differential
• Differential cover gasket × 1 — Use OEM specification
• Differential bearing shim set × 1 — Use OEM shim kit for backlash adjustment
• Gear marking compound × 1 — For pattern verification
• RTV silicone gasket maker (if gasket not available) × 1 — Hyundai approved RTV

Fluids

• 75W-90 GL-5 Gear Oil — 2.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen rear wheel lug nuts before lifting vehicle
3. Raise vehicle and support securely on jack stands at manufacturer lift points
4. Remove both rear wheels
5. Place drain pan under rear differential
6. Allow differential to cool to ambient temperature if recently driven
7. Clean exterior of differential housing with brake cleaner to prevent contamination

Procedure

1. 1

   Drain differential fluid
   Remove the differential cover bolts in a crisscross pattern, starting from the top. Once loose, carefully pry cover away from housing at bottom edge to allow fluid to drain into pan. Remove cover completely and clean all old gasket material from both cover and housing mating surfaces using a plastic scraper. Inspect drained fluid for metal particles or debris indicating wear.
2. 2

   Mark and measure gear position
   Before disassembly, rotate the ring gear and inspect tooth contact pattern. Use a paint marker to mark the relationship between ring gear and differential case for reassembly reference. Install dial indicator on housing and measure ring gear backlash at 4 points around the gear (90 degrees apart). Record all measurements - backlash should be 0.10-0.18mm (0.004-0.007 inches). These measurements are critical for reassembly verification.
3. 3

   Remove differential assembly from housing
   Remove the differential bearing cap bolts and mark caps for reinstallation position (they are not interchangeable). Carefully pry differential assembly upward out of housing using pry bars on both sides simultaneously. Remove bearing races from housing and keep matched with their respective bearings. Place differential assembly on clean work surface.
4. 4

   Disassemble ring gear from carrier
   Remove ring gear mounting bolts in a crisscross pattern. The ring gear is typically a tight fit on the carrier - tap gently with brass punch if needed to separate. Mark orientation of ring gear to carrier before removal. Inspect ring gear for wear, scoring, or damage.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Remove differential side bearings
   Using a bearing puller, carefully remove both side bearings from differential carrier. Note the position and thickness of any shims behind bearings - measure and record shim thickness on each side. Keep bearings and shims separated and labeled for their respective sides. Inspect bearing races for pitting or wear.
6. 6

   Disassemble differential case
   Remove the differential pinion shaft retaining pin by driving it out with a punch. Slide pinion shaft out of case. Remove pinion gears and side gears, keeping track of their orientation. Note the position of any thrust washers behind gears. This exposes the limited slip clutch packs.
7. 7

   Remove old clutch packs and inspect
   Carefully remove the clutch pack assemblies from both sides of the differential case. The clutch packs consist of alternating friction discs and steel plates. Lay them out in order removed to compare with new pack. Measure total clutch pack stack height with micrometer and record. Inspect case for wear, scoring, or heat discoloration. Clean all components thoroughly with brake cleaner.
8. 8

   Install new clutch packs
   Install new limited slip clutch packs according to manufacturer instructions, ensuring proper orientation of friction and steel plates. Alternate friction discs with steel plates as specified in clutch pack kit instructions. Soak friction discs in 75W-90 gear oil for 15 minutes before installation. Measure new clutch pack stack height and compare to original - adjust shims if necessary per manufacturer specifications. Ensure clutch pack moves freely but with appropriate resistance.
9. 9

   Reassemble differential internals
   Install side gears with thrust washers into case, followed by pinion gears. Rotate gears to align pinion shaft holes. Insert pinion shaft and verify smooth rotation of all gears. Install new pinion shaft retaining pin and ensure it is fully seated. Check that clutch packs engage properly when side gears are rotated in opposite directions.
10. 10

    Install ring gear and bearings
    Align ring gear to carrier using reference marks made during disassembly. Install ring gear mounting bolts and torque in a crisscross pattern to specification. Install original shims on differential carrier, then press or drive side bearings onto carrier using appropriate driver that contacts inner race only. Verify bearings are fully seated against shoulders.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
11. 11

    Install differential assembly in housing
    Install bearing races into housing if removed. Carefully lower differential assembly into housing, ensuring bearing races engage properly. Install bearing caps in their original positions (check alignment marks). Install cap bolts and torque to specification. Rotate differential by hand to ensure it turns smoothly without binding.
12. 12

    Check and adjust backlash
    Install dial indicator and measure ring gear backlash at 4 points around gear. Compare to original measurements. Backlash should be 0.10-0.18mm (0.004-0.007 inches). If adjustment needed, remove bearing caps and adjust shim thickness: increase shim on ring gear side to decrease backlash, or increase shim on opposite side to increase backlash. Make adjustments in 0.05mm increments. Re-torque bearing caps and recheck backlash after any adjustment.
13. 13

    Verify gear contact pattern
    Apply thin coat of gear marking compound to 3-4 teeth on ring gear. Rotate pinion in both directions while applying resistance to ring gear. Inspect tooth contact pattern - it should be centered on tooth face with proper length and width. Adjust if necessary by changing shim thickness. Proper pattern is critical for gear longevity.
14. 14

    Install differential cover
    Clean cover and housing mating surfaces thoroughly. Install new gasket or apply thin bead of RTV silicone to cover (follow gasket manufacturer instructions for cure time if using RTV). Position cover on housing and install bolts finger-tight. Torque cover bolts in a crisscross pattern to specification, working from center outward.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
15. 15

    Refill differential with gear oil
    Locate fill plug on differential housing (typically on front or side). Remove fill plug. Using gear oil pump or fluid transfer syringe, add 75W-90 GL-5 gear oil until it begins to drip from fill hole. Install fill plug. Wipe exterior clean. Install rear wheels and torque lug nuts in star pattern to specification.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all bearing caps are installed in their original positions with alignment marks properly oriented
2. Verify differential rotates smoothly by hand before installing cover
3. Allow RTV silicone to cure per manufacturer instructions before filling with oil if RTV was used instead of gasket
4. Double-check that all fasteners are torqued to specification before lowering vehicle

Verification

• Lower vehicle and test drive in a safe area with multiple turns in both directions
• Listen for abnormal noises from rear differential during turns and acceleration
• Verify limited slip function by performing controlled acceleration on low-traction surface - both rear wheels should receive power
• After 50-100 miles, recheck differential cover for leaks and retorque cover bolts if necessary
• Monitor differential fluid level at first oil change interval and inspect for metal particles indicating problems

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