hyundai elantra drive shaft & axle

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Hyundai Elantra Xd 2003 G2.0 DOHC Drive Shaft & Axle

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  • 11/15/13 https://www.hyundaitechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=HY&area=HMA&langcode=ENG&modelid=XD13&modeldesc=EL

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    ELANTRA(XD) > 2003 > G 2.0 DOHC > Drive Shaft & Axle

    Drive Shaft & Axle > Drive Shaft > Front Drive Shaft Assembly > INSPECTION

    INSPECTION

    1. Check the driveshaft boots for damage and deterioration.

    2. Check the ball joints for wear and damage.

    3. Check the splines for wear and damage.

    4. Check the dynamic damper for cracks and wear.

    Drive Shaft & Axle > Drive Shaft > Front Driveshaft > COMPONENTS

    COMPONENTS

    Drive Shaft & Axle > Drive Shaft > Front Driveshaft > INSPECTION

    INSPECTION

    1. Check the driveshaft boots for damage and deterioration.

    2. Check the ball joints for wear and damage.

    3. Check the splines for wear and damage.

    4. Check the dynamic damper for cracks and wear.

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    Drive Shaft & Axle > Drive Shaft > Front Driveshaft > INSTALLATION

    INSTALLATION

    1. Apply gear oil on the driveshaft splines and differential case contacting surface.

    2. Before installing the driveshaft, set the opening side of the circlip facing downward.

    3. After installation, check that the driveshaft cannot be removed by hand.

    4. Assemble the dust cover, the hub the brake disc and the wheel bearing to the knuckle.

    5. Install the B.J. into the knuckle.

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    6. In practice, the knuckle should be installed in the lower arm the moment the B.J. is installed in the knuckle. Be

    careful not to damage the boot.

    7. Install the knuckle in the strut assembly with the tightening torque, 75~90 Nm (750~900 kgcm, 54~65 lbft).

    8. Install the lower arm in the knuckle with the tightening torque 60~72 Nm (600~720 kgcm, 43~52 lbft).

    9. After the installation, check on the driveshaft for stability by hand.

    10. After installing the washer with convex surface outward, install the castle nut and the split pin.

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    11. Install the wheel and tire.

    Drive Shaft & Axle > Drive Shaft > Front Driveshaft > REMOVAL

    REMOVAL

    1. Loosen the wheel nuts slightly.

    2. Raise the front of the vehicle and support it with safety stands in a proper location.

    3. Loosen the wheel nuts thoroughly and remove the front wheel.

    4. Remove the split pin, the castle nut and the washer from the front hub.

    5. Disconnect the tie rod end ball joint from the knuckle by using the Special Tool(09568-34000) after removing the split

    pin and the castle nut.

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    6. Remove the caliper assembly from the knuckle and suspend it with a wire.

    7. Disconnect the lower arm ball joint from the knuckle by using the Special Tool (09568-34000).

    8. Remove the vehicle speed sensor from the knuckle.

    9. Disconnect the strut upper mounting bolts.

    10. Using a plastic hammer, disconnect the driveshaft from the axle hub.

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    11. Push the axle hub outward and separate the driveshaft from the axle hub.

    12. Drain the transmission fluid before the driveshaft is removed.

    13. Insert a pry bar between the transaxle case and joint case, and separate the driveshaft from the transaxle case.

    a. Use a pry bar being careful not to damage the transaxle and joint.

    b. Do not insert the pry bar too deep, as this may cause damage to the oil seal. [max. depth : 7mm (0.28 in.)]

    c. Do not pull the driveshaft by excessive force it may cause components inside the B.J. or T.J. joint kit to dislodge

    resulting in a torn boot or a damaged bearing.

    14. Pull out the driveshaft from the transaxle case.

    a. Plug the hole of the transaxle case with the oil seal cap to prevent contamination.

    b. Support the driveshaft properly.

    c. Replace the retainer ring whenever the driveshaft is removed from the transaxle case.

    Drive Shaft & Axle > Drive Shaft > Front Driveshaft (DOJ-BJ Type) > COMPONENTS

    COMPONENTS

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    Drive Shaft & Axle > Drive Shaft > Front Driveshaft (DOJ-BJ Type) > DISASSEMBLY

    DISASSEMBLY

    a. Do not disassemble the B.J. assembly.

    b. Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.

    c. The boot band should be replaced with a new one.

    1. Remove the D.O.J. boot bands and pull the D.O.J. boot from the D.O.J. outer race.

    Be careful not to damage the boot.

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    2. Remove the circlip with a flat-tipped screwdriver.

    3. Pull out the driveshaft from the D.O.J. outer race.

    4. Remove the snap ring and take out the inner race, cage and balls as an assembly.

    5. Clean the inner race, cage and balls without disassembling.

    6. Remove the B.J. boot bands and pull out the D.O.J. boot and B.J. boot.

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    If the boot is to be reused, wrap tape around the driveshaft splines to protect the boot.

    Drive Shaft & Axle > Drive Shaft > Front Driveshaft (DOJ-BJ Type) > INSPECTION

    INSPECTION

    1. Check the D.O.J. outer race, inner race, cage and balls for rust or damage.

    2. Check splines for wear.

    3. Check for water, foreign matter, or rust in the B.J. boot.

    When the B.J. assembly is to be reused, do not wipe away the grease. Check that there are no foreign substances

    in the grease. If necessary, clean the B.J. assembly and replace grease.

    Drive Shaft & Axle > Drive Shaft > Front Driveshaft (DOJ-BJ Type) > REASSEMBLY

    REASSEMBLY

    1. Wrap tape around the driveshaft splines (D.O.J. side ) to prevent damage to the boots.

    2. Apply grease to the driveshaft and install the boots. (refer to 'LUBRICANTS', See page DS-3)

    3. To install the dynamic damper, keep the B.J. and driveshaft in a straight line and secure the dynamic damper with

    the dynamic damper band in the direction illustrated.

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    4. Apply the specified grease to the inner race and cage. Install the cage so that it is offset on the race as shown.

    Use the grease included in the repair kit.

    5. Apply the specified grease to the cage and fit the balls into the cage.

    6. Position the chamfered side as shown in the illustration. Install the inner race on the driveshaft, and then the snap

    ring.

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    7. Apply the specified grease to the outer race and install the B.J. outer race onto the driveshaft.

    8. Apply the specified grease into the D.O.J boot and install the boot with a clip. (refer to 'LUBRICANTS', See page DS-

    3)

    9. Tighten the D.O.J. boot bands.

    10. Add the specified grease to the B.J. as much as was wiped away at inspection.

    11. Install the boots.

    12. Tighten the B.J. boot bands.

    13. To control the air in the D.O.J. boot, keep the specified distance between the boot bands when they are tightened.

    Standard value (A) mm (in.)

    LH 513.22 (20.200.08)

    RH 796.22 (31.350.08)

    Drive Shaft & Axle > Drive Shaft > Front Driveshaft (TJ-BJ Type) > COMPONENTS

    COMPONENTS

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    Drive Shaft & Axle > Drive Shaft > Front Driveshaft (TJ-BJ Type) > DISASSEMBLY

    DISASSEMBLY

    a. Do not disassemble the B.J. assembly.

    b. Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.

    c. The boot band should be replaced with a new one.

    1. Remove the T.J. boot bands and pull the T.J. boot from the T.J. case.

    Be careful not to damage the boot.

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    2. Remove the snap ring and spider assembly from the driveshaft.

    3. Clean the spider assembly.

    4. Remove the B.J. boot bands and pull out the T.J. boot and B.J. boot.

    If the boot is to be reused, wrap tape around the driveshaft splines to protect the boot.

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    Drive Shaft & Axle > Drive Shaft > Front Driveshaft (TJ-BJ Type) > INSPECTION

    INSPECTION

    1. Check the driveshaft spline for wear or damage.

    2. Check that there is no water or foreign material in the B.J.

    3. Check the spider assembly for roller rotation, wear or corrosion.

    4. Check the groove inside the T.J. case for wear or corrosion.

    5. Check the dynamic damper for damage or cracks.

    Drive Shaft & Axle > Drive Shaft > Front Driveshaft (TJ-BJ Type) > REASSEMBLY

    REASSEMBLY

    1. Wrap tape around the driveshaft splines (T.J. side) to prevent damage to the boots.

    2. Apply grease to the driveshaft and install the boots. (refer to 'LUBRICANTS', See page DS-3)

    3. To install the dynamic damper, keep the B.J. and driveshaft in a straight line and secure the dynamic damper with

    the dynamic damper band in the direction illustrated.

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    4. Apply grease into the T.J. boot and install the boot. (refer to 'LUBRICANTS', See page DS-3)

    5. Tighten the T.J. boot bands.

    6. Add the specified grease to the B.J. as much as was wiped away at inspection.

    7. Install the boots.

    8. Tighten the B.J. boot bands.

    9. To control the air in the T.J. boot, keep the specified distance between the boot bands when they are tightened.

    Standard value (A) mm (in.)

    LH 514.2 2 (20.24 0.08)

    RH 799.2 2 (31.46 0.08)

    Drive Shaft & Axle > Front Axle > Front Hub/Knuckle > COMPONENTS

    COMPONENTS

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    Drive Shaft & Axle > Front Axle > Front Hub/Knuckle > DISASSEMBLY

    DISASSEMBLY

    1. After removing the screws(2) mounting the brake disc, remove the brake disc from the hub.

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    2. Remove the snap ring.

    3. Install the Special Tools as illustrated.

    4. Remove the hub from the knuckle by turning the Special Tool.

    5. Remove the Special Tool and dust cover.

    6. Remove the bearing inner race from the hub by using the Special Tool (09495-33000, 09551-31000).

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    7. Using the Special Tool (09495 - 33100, 09517 - 29000), remove the wheel bearing outer race from the knuckle.

    Drive Shaft & Axle > Front Axle > Front Hub/Knuckle > INSPECTION

    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.

    Drive Shaft & Axle > Front Axle > Front Hub/Knuckle > INSTALLATION

    INSTALLATION

    1. Installation is in the reverse order of removal.

    Tighten the components below to the specified torque as follows :

    Items Torque Nm (kgcm, lbft)

    Driveshaft nut200 ~ 260

    (2000 ~ 2600, 159 ~ 192)

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    Lower arm ball joint to knuckle nut 60 ~ 72 (600 ~ 720, 44 ~ 53)

    Knuckle to strut assembly nut130 ~ 150

    (1300 ~ 1500, 96 ~ 111)

    2. Install the strut assembly and the driveshaft in the knuckle.

    3. Connect the wheel speed sensor.

    4. Install the caliper assembly in the hub and knuckle assembly which the brake disc is already installed.

    5. Tighten the lower arm ball joint nut.

    6. Tighten the tie rod end ball joint nut and insert the split pin.

    7. Insert the washer and tighten the castle nut.

    8. Insert the split pin.

    9. Install the wheel and tire and tighten the wheel nuts.

    Drive Shaft & Axle > Front Axle > Front Hub/Knuckle > REASSEMBLY

    REASSEMBLY

    1. Apply multi-purpose grease to the contacting surface of the knuckle hub and bearing thinly.

    2. Using the Special Tool (09495-33100), press-in the bearing to the knuckle.

    a. Press-in the outer race of the wheel bearing to prevent damage to the bearing assembly.

    b. When installing a bearing assembly, always use a new one.

    c. The right and the left bearing must be made in the same company.

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    3. Install the snap ring.

    4. Install the dust cover.

    5. Using the Special Tool (09495-33100), press-in the hub to the knuckle.

    Press-in the inner race of the wheel bearing to prevent damage to the bearing assembly.

    6. Install the brake disc.

    7. Tighten the hub and the knuckle to the specified torque by using the Special Tool (09517-21500).

    Specified torque Nm (kgcm, ftlb) :200 ~ 260 (2000 ~ 2600, 159 ~ 192)

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    8. Rotate the hub several times to seat the bearing.

    9. Measure the hub bearing starting torque.

    Hub bearing starting torque [Limit] :1.8 Nm (18 kgcm, 16 lbin) or less

    10. If the starting torque is 0 Ncm (0 in.lbs.), measure the hub bearing axial play.

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    11. If the hub axial play exceeds the limit while the nut is tightened to 200~260 Nm (2000~2600Kgcm, 159~192 ftlb),

    the bearing, hub and knuckle are not installed correctly. Repeat the disassembly and assembly procedure.

    Hub bearing axial play [Limit] :0.008 mm (0.0003 in.) or less

    12. Remove the Special Tool (09517-21500).

    13. Fix the brake disc with the mounting screws.

    Drive Shaft & Axle > Front Axle > Front Hub/Knuckle > REMOVAL

    REMOVAL

    1. Remove the front wheel.

    2. Remove the split pin, driveshaft nut and the washer from the front hub.

    3. Disconnect the tie rod end ball joint from the knuckle by using the Special Tool (09568 - 34000).

    Be sure to tie the special tool (09568 - 34000) to the near part with cord not to fall.

    4. Remove the front caliper assembly from the knuckle and suspend it with a wire.

    5. Disconnect the lower arm ball joint from the knuckle by using the Special Tool (09568 - 34000).

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    6. Remove the vehicle speed sensor from the knuckle.

    7. Disconnect the strut assembly from the knuckle.

    8. Disconnect the driveshaft from the hub.

    9. Remove the hub and knuckle as an assembly.

    Drive Shaft & Axle > General > LUBRICANTS

    LUBRICANTS

    Items Recommended Quantity

    B.J.95+D.O.J.95 Type driveshaft (For 2.0L M/T)

    B.J. boot grease

    CENTOPLEX 278M/136K

    CASMOLY BJ

    ROLLUBE BJ

    Sunlight SW-2

    Joint :60 3gr.

    Boot : 55 3gr.

    D.O.J. boot grease

    AMBLYGON TA 10/2A

    CASMOLY DOJ

    DURALUBE DOJ

    Variant S-R2

    Joint :60 3gr.

    Boot : 40 3gr.

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    B.J.92+T.J.92 Type driveshaft (For 2.0L A/T)

    B.J. boot grease

    CENTOPLEX 278M/136K

    CASMOLY TJ

    ROLLUBE TJ

    Sunlight SW-2

    Joint :60 3gr.

    Boot : 55 3gr.

    T.J. boot grease

    KLK TJ 41-182

    CASMOLY TJ

    ROLLUBE TJ

    Oneluber TJ

    Joint : 100 3gr.

    Boot : 45 3gr.

    Drive Shaft & Axle > General > SPECIAL TOOLS

    SPECIAL TOOLS

    Tool (Number and Name) Illustration Use

    09495-33000

    Puller

    Removal of wheel bearing inner race from the hub.

    09495-33100

    Center bearing remover and

    installer

    a. Removal of wheel bearing from the knuckle. (Use

    with 09517-29000)

    b. Installation of hub to the knuckle.

    09517-21500

    Front hub remover and

    installer

    a. Removal of front hub from the knuckle. (Use with

    09517-29000)

    b. Measurement of front wheel bearing pre-load. (Use

    with 09532-11600)

    09517-29000

    Knuckle arm bridgea. Removal of front hub from the knuckle. (Use with

    09517-21500)

    b. Removal of wheel bearing outer race from the

    knuckle. (Use with 09495-33100)

    09532-11600

    Preload socket

    Measurement of front wheel bearing pre-load. (Use with

    09517-21500)

    09532-31200A

    Oil seal installer

    Installation of wheel bearing to the knuckle.

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    09568-34000

    Ball joint puller

    Seperation of front lower arm and tie rod end ball joint.

    Drive Shaft & Axle > General > SPECIFICATIONS

    SPECIFICATIONS

    Driveshaft

    Engine type

    Outer joint type

    Inner joint type

    2.0L M/T

    B.J. 95

    D.O.J. 95

    2.0L A/T

    B.J. 92

    T.J. 92

    Maximum permissible joint angle

    B.J.

    D.O.J.

    T.J.

    46or more

    22or more

    45.8or more

    23or more

    Hub end play mm(in.) 0.008 (0.0003) or less

    Wheel bearing starting torque Nm (kgcm, lbft) 1.8 (18, 1.33) or less

    B. J. : Birfield Joint

    D.O.J. : Double Offset Joint

    T. J. : Tripod Joint

    M/T: Manual Transaxle

    A/T : Automatic Transaxle

    Drive Shaft & Axle > General > TIGHTENING TORQUE

    TIGHTENING TORQUE

    Nm Kgcm lbft

    Castle nut 200 ~ 260 2000 ~ 2600 148 ~ 192

    Knuckle to strut assembly nut 130 ~ 150 1300 ~ 1300 96 ~ 111

    Lower arm ball joint to knuckle nut 60 ~ 72 600 ~ 720 44 ~ 53

    Tie rod end to knuckle 24 ~ 34 240 ~ 340 18 ~ 25

    Brake caliper to knuckle 69 ~ 85 690 ~ 850 51 ~ 63

    Wheel nut 90 ~ 110 900 ~ 1100 66 ~ 81

    Rear hub bearing flange nut 200 ~ 260 2000 ~ 2600 148 ~ 192

    Rear brake to rear axle carrier mounting bolt 65 ~ 75 650 ~ 750 48 ~ 55

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    Rear strut to carrier nut 110 ~ 130 1100 ~ 1300 81 ~ 96

    Trailing arm to rear axle carrier mounting nut 100 ~ 120 1000 ~ 1200 74 ~ 89

    Rear suspension arm to rear axle carrier mounting nut 160 ~ 180 1600 ~ 1800 118 ~ 133

    Brake disc to hub 5 ~ 6 50 ~ 60 3.7 ~ 4.4

    Replace self-locking nuts with new ones after removal.

    Drive Shaft & Axle > Rear Axle > Rear Axle/Hub > COMPONENTS

    COMPONENTS

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    Drive Shaft & Axle > Rear Axle > Rear Axle/Hub > INSPECTION

    INSPECTION

    1. Check the oil seal for cracks or damage.

    2. Check the rear hub bearing for wear or damage.

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    3. Check the rear rotor for chipped teeth.

    4. Check the rear carrier for cracks.

    Drive Shaft & Axle > Rear Axle > Rear Axle/Hub > INSTALLATION

    INSTALLATION

    1. After tightening the flange nut, caulk the concave portion of the spindle by crimping the nut.

    Replace the flange nut with new ones after removal.

    2. Installation of the rear speed sensor (For vehicles equipped with ABS) :

    Insert a feeler gauge into the space between the pole piece of the speed sensors and the rotor teeth surface, and

    then tighten the speed sensors at the position where the clearance at all places is within the standard value.

    Standard value :

    Clearance : 0.2-1.3 mm (0.008-0.051 in.)

    3. Install the hub cap.

    Drive Shaft & Axle > Rear Axle > Rear Axle/Hub > REMOVAL

    REMOVAL

    1. Loosen the wheel nuts slightly.

    2. Raise the rear of the vehicle.

    3. Loosen the wheel nuts thoroughly and remove the rear wheel and tire.

    4. Remove the hub cap with a driver and a hammer.

    5. Remove the flange nut and the tongued washer.

    6. Remove the rear wheel speed sensor (for vehicles equipped with Anti-lock Brake System).

    When removing the speed sensor from the adapter be careful for the end of the pole piece not to strike the teeth on

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    the rotor or other components.

    7. Remove the caliper assembly and suspend it with a wire.

    8. Remove the brake disc and hub assembly.

    9. Remove the brake disc from the hub assembly by loosening the screw.

    a. The rear hub assembly should not be disassembled.

    b. (For vehicles equipped with ABS)

    Care must be taken not to scratch or damage the teeth of the rotor. The rotor must never be dropped. If the teeth

    of the rotor are chipped, it results in deformation of the rotor. It will make it impossible to detect the wheel rotation

    speed accurately and to operate the system normally.

    Drive Shaft & Axle > Rear Axle > Rear Axle/Hub (4WD) > INSPECTION

    INSPECTION

    1. Check the oil seal for cracks or damage.

    2. Check the rear hub bearing for wear or damage.

    3. Check the rear rotor for chipped teeth.

    4. Check the rear carrier for cracks.

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    Drive Shaft & Axle > Troubleshooting > SYMPTOM TROUBLESHOOTING

    TROUBLESHOOTING

    Symptom Possible cause Remedy

    Vehicle pulls to one side Galling of drive shaft ball joint Replace

    Wear, rattle or galling of wheel bearing Replace

    Defective front suspension and steering Adjust or replace

    Vibration Wear, damage or bending of drive shaft Replace

    Drive shaft rattle and hub serration Replace

    Wear, rattle or sintering of wheel bearing Replace

    Shimmy Improper wheel balance Adjust or replace

    Defective front suspension and steering Adjust or replace

    Excessive noise Wear, damage or bending of drive shaft Replace

    Drive shaft rattle and hub serration Replace

    Drive shaft rattle and side gear serration Replace

    Wear, rattle or galling of wheel bearing Replace

    Loose hub nut Adjust or replace

    Defective front suspension and steering Adjust or replace