Kia Optima Hybrid: Driveshaft Assembly / Front Driveshaft Repair procedures

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual / Driveshaft and axle / Driveshaft Assembly / Front Driveshaft Repair procedures

Replacement

1.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

Remove wheel nuts, front wheel and tire from front hub.

Tightening torque:

88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

Be careful not to damage to the wheel nuts when removing the front wheel and tire.

Remove the brake caliper mounting bolts , and then hold the brake caliper assembly (A) with wire.

Tightening torque:

78.4 ~ 98.0 N.m (8.0 ~ 10.0 kgf.m, 57.8 ~ 72.3 lb-ft)

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

Tightening torque :

215.7 ~ 254.9 N.m (22.0 ~ 26.0 kgf.m, 159.1 ~ 188.0 lb-ft)

Remove the tie rod end ball joint (A) from the knuckle.

(1)	Remove the split pin (C).

(2)

Remove the castle nut (B).

Tightening torque:

34.3 ~ 44.0 N.m (3.5 ~ 3.4 kgf.m, 25.3 ~ 32.5 lb-ft)

Loosen the mount bolt and then remove the wheel speed sensor (A) from knuckle.

Tightening torque:

6.8 ~ 10.7 N.m (0.7 ~ 1.1 kgf.m, 5.0 ~ 7.9 lb-ft)

Loosen the bolt & nut and then remove the knuckle from the strut assembly (A).

Tightening torque:

156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)

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

Insert a pry bar between the transaxle case and joint case, and separate the driveshaft (A) 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.

10.	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

•	Do not disassemble the BJ assembly.

•	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).

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.

7.	Clean the spider assembly.

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.

Apply grease to the joint boot on the side of the wheel and install the boot.

Lubricants Quantity:

GRB006 (UREA) 105g (3.7 OZ.)

Using the SST (09495-3K000), secure the boot band.

Clearance (A): 2.0 mm (0.079 in) or less

4.	To install the dynamic damper (A), keep the shaft in a straight line and assemble the dynamic damper with the bands(B).

5.	Assemble the transaxle side joint boot and bands.

Using the alignment marks (D) made during disassembly as a guide, install the spider assembly (A) and snap ring (B) on the driveshaft splines (C).

Lubricants Quantity:

SH06-VX21 (UREA) 145g (5.1 OZ.)

7.	Add specified grease to the joint boot as much as it was wiped away at inspection.

8.	Install the both boot band.

Front Driveshaft Components and Components Location

Component location 1. Driveshaft (LH) 2. Driveshaft (RH) Components 1. BJ assembly2. Circlip3. BJ boot band4. BJ boot5. Dynamic damper band6. Dynamic damper7. Shaft8. TJ boot band9. TJ boot10. Spider assembly11. ...

Rear Axle Assembly

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