Hyundai Sonata: Front Driveshaft Repair procedures - Driveshaft Assembly - Driveshaft and axleHyundai Sonata: Front Driveshaft Repair procedures

Removal
1.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the wheel cap (A).

   
Be careful not to damage to the wheel cap (A) when removing the it.
3.
Remove the front wheel and tire (A) from front hub.

Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

4.
Remove driveshaft nut (A) from the front hub under applying the brake.

Tightening torque :
274.6 ~ 294.2 N.m (28.0 ~ 30.0 kgf.m, 202.5 ~ 217.1 lb-ft)

   
The front hub coking nut should be replaced with new ones.
After installation coking nut (A), stake the coking nut using a chisel and hammer as shown in the illustration below.

   
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
5.
Remove the tie rod end ball joint (C) from the knuckle.
(1)
Remove the split pin (A).
(2)
Remove the castle nut (B).

Tightening torque :
34.3 ~ 44.0 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.5 lb-ft)

6.
Loosen the lower arm mounting and then remove the lower arm (A).
(1)
Remove the split pin (B).
(2)
Loosen the mounting nut and bolt.

7.
Loosen the stabilizer link (A) and remove it from the shock absorber.

Tightening torque :
98.1 ~ 117.7 N.m (10.0 ~ 12.0 kgf.m, 72.3 ~ 86.8 lb-ft)

8.
Disconnect the driveshaft (A) from the front hub assembly..

9.
Loosen the inner shaft bearing mounting bolts(A). [T-GDI ONLY]

Tightening torque :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

10.
Insert a pry bar (A) between the transaxle case and joint case, and separate the drive shaft (B) from the transaxle case.

   
Use a pry bar (A) being careful not to damage the transaxle and joint.
Do not insert the pry bar (A) too deep, as this may cause damage to the oil seal.
Do not pull the driveshaft by excessive force it may cause components inside the joint kit to dislodge resulting in a torn boot or a damaged bearing.
Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
Support the driveshaft properly.
Replace the retainer ring whenever the driveshaft is removed from the transaxle case.
11.
Install in the reverse order of removal.
Inspection
1.
Check the driveshaft boots for damage and deterioration.
2.
Check the driveshaft spline for wear or damage.
3.
Check that there is no water or foreign material in the joint.
4.
Check the spider assembly for roller rotation, wear or corrosion.
5.
Check the groove inside the joint case for wear or corrosion.
6.
Check the dynamic damper for damage or cracks.
Disassembly
   
Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.
The boot band should be replaced with a new one.
1.
Remove the circlip (B) from the driveshaft spline (A).

2.
Remove both boot bands from the transaxle side joint(TJ) case.

3.
Pull out the boot from transaxle side joint case (B).
4.
While dividing joint(TJ) boot (A) of the transaxle side, wipe the grease in TJ case (B) and collect them respectively.

   
Make alignment marks (D) on spider roller assembly (A), joint case (B), and shaft spline (C) to aid reassembly.

5.
Remove the snap ring (A) from the shaft.

6.
Remove the spider assembly (B) from the driveshaft (A) using the special tool (09495-33000).

7.
Clean the spider assembly.
8.
Remove the boot (A) of the transaxle side joint(TJ).
   
For reusing the boot (A), wrap tape (B) around the driveshaft splines (C) to protect the boot (A).

9.
Using a plier or flat-tipped (-) screwdriver, remove the both side of clamp (B) of the dynamic damper (A).

10.
Fix the driveshaft (A) with a vice (B) as illustrated.

11.
Apply soap powder on the shaft to prevent being damaged between the shaft spline and the dynamic damper when the dynamic damper is removed.
12.
Saperate the dynamic damper (A) from the shaft (B) carefully.

13.
Using a plier or flat-tipped (-) screwdriver, remove the BJ boot band on the side of wheel.

14.
Pull out the joint (BJ) on the side of wheel into transaxle direction.
   
Be careful not to damage the boot.
Reassembly
1.
Wrap tape around the driveshaft spline(TJ) to prevent damage to the boots.
2.
Using the alignment marks (D) made during disassembly as a guide, install the spider assembly (A) and retainer ring (B) on the driveshaft splines (C).

3.
Add specified grease to the joint boot as much as it was wiped away at inspection.
4.
Install the both boot band.
5.
To control the air in the TJ boot, keep the specified distance between the boot bands when they are tightened.
Items
Distance (L) mm(in)
LH side
RH side
THETA2.4 GDI A/T
530.5
843.5
GAMMA1.6 T-GDI 7DCT
517.8
509.5
THETA2.0 T-GDI A/T
518.5
524

6.
Using the SST, secure the TJ boot bands.

Clearance (A):
2.0 mm (0.0787 in.) or less

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