I'm changing the bearings in a Kia Sorento differential(third member set-up with crush spacer)and I am in a bit of a quandary. Pinion height as measured requires a shim that is out of the range of those available. It needs to be thinner, so I can't stack them.
I'm pretty sure of my measurements. I measured the original set up before disassembly and it was within a thou or two of the correct height. With the new bearings,with preload, its 0.020" too high. The entire factory shim range is only 0.015" from thickest to thinnest.
I'm trying to determine my best option. I've looked at just about everything I can find on YouTube and done numerous internet searches. Any advice from someone who does this for a living or who has a good amount of personal experience would be greatly appreciated.
Thanks,
Bob

so with no shims in its still .020 too high?

ED

correction: I'm .018" too low
The existing shim is 0.1275". Without the shim it would be 0.1095 too low. The thinnest shim is .1212".

I'm considering putting it together with the ring gear, setting the backlash, and seeing if I can get a good contact pattern and just go with it.

Is this OEM gear or aftermarket? Is this with new crush spacer?

I assume you went from the case opening to the top of the pinion gear, and now it is deeper by .018 than it was before. It will never set up correctly with that much difference. The factory manual setup just gets you close, it is the gear pattern that determines the shimming. What you shoot for is a good pattern with the correct back lash.

It is OEM, I'm just replacing the bearings. I will install a new crush spacer on final assembly.

I measured from the top of the pinion to the bottom of the carrier bearing housing then added in half the diameter of the carrier bearing outer race to get the distance from the top of pinion to the center of the ring gear.

I am going to install the ring gear and check the pattern tonight. Fingers crossed.