Kia Optima Hybrid: Front Axle Assembly / Front Hub / Knuckle Repair procedures

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual / Driveshaft and axle / Front Axle Assembly / Front Hub / Knuckle 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 ~ 4.5 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.

Loosen the bolt & nut and then remove the lower arm (A).

Tightening torque:

98.0 ~ 117.6 N.m (10.0 ~ 12.0 kgf.m, 72.3 ~ 86.7 lb-ft)

10.

Remove the front lower arm from the front knuckle using the SST (0K545-A9100).

(1)	After removing bolts from the front knuckle, install and tighten the sub body bolt (A) .

(2)	Input the sub body (A) between the front knuckle and the sub body bolt.

(3)	Tighten bolt (B) of the sub body bolt to broaden the gap of the front knuckle.

(4)

Install the safe wire (A).

Install a safe wire on the front strut to prevent dropping the SST and hurting technicians.

(5)	Install the main body, between the front strut and the lower arm.

(6)	To avoid the main body coming off, install a fixing clamp (A) beside the main body.

(7)	After installing a fixing clamp, rotate the handle (B) clock wise till the clamp is fixed on a lower arm.

(8)	Tighten a main body bolt (A) of the slowly and remove the lower arm from the front knuckle.

11.	Install in the reverse order of removal.

Inspection

1.	Check the hub for cracks and the splines for wear.

2.	Check the brake disc for scoring and damage.

3.	Check the knuckle for cracks

4.	Check the bearing for cracks or damage.

Disassembly

1.	Remove the snap ring (A).

Remove the hub assembly from the knuckle assembly.

(1)	Install the front knuckle assembly (A) on press.

(2)	Lay a suitable adapter (B) upon the hub assembly shaft.

Remove the hub bearing inner race from the hub assembly.

(1)	Install a suitable tool (A) for removing the hub bearing inner race on the hub assembly.

(2)	Lay the hub assembly and tool (A) upon a suitable adapter (B).

(3)	Lay a suitable adapter (C) upon the hub assembly shaft.

(4)	Remove the hub bearing inner race (D) from the hub assembly by using press.

Remove the hub bearing outer race from the knuckle assembly.

(1)	Lay the hub assembly (A) upon a suitable adapter (B).

(2)	Lay a suitable adapter (C) upon the hub bearing outer race.

(3)	Remove the hub bearing outer race from the knuckle assembly by using press.

5.	Replace hub bearing with a new one.

Reassembly

Install the hub bearing to the knuckle assembly.

(1)	Lay the knuckle assembly (A) on press.

(2)	Lay a new hub bearing upon the knuckle assembly (A).

(3)	Lay a suitable adapter (B) upon the hub bearing.

(4)	Install the hub bearing to the knuckle assembly by using press.

–	Do not press against the inner race of the hub bearing because that can cause damage to the bearing assembly.

–	Always use a new wheel bearing assembly.

Install the hub assembly to the knuckle assembly.

(1)	Lay the hub assembly (A) upon a suitable adapter .

(2)	Lay the knuckle assembly (B) upon the hub assembly (A).

(3)	Lay a suitable adapter (C) upon the hub bearing.

(4)	Install the hub assembly (A) to the knuckle assembly (B) by using press.

Do not press against the inner race of the hub bearing because that can cause damage to the bearing assembly.

3.	Install the snap ring (A).

Front Hub / Knuckle Components and Components Location

Components 1. Driveshaft nut2. Brake disc3. Hub4. Wheel bearing5. Snap ring6. Dust cover7. Knuckle8. Driveshaft ...

Driveshaft Assembly

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