Hyundai Elantra Drive Shaft Inspection and Repair Guide

11/15/13
https://www.hyundaitechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=HY&area=HMA&langcode=ENG&modelid=XD13&modeldesc=EL
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 DS3) 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) LH RH mm (in.) 513.22 (20.200.08) 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) LH RH mm (in.) 514.2 2 (20.24 0.08) 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 Driveshaft nut Torque Nm (kgcm, lbft) 200 ~ 260 (2000 ~ 2600, 159 ~ 192)
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Lower arm ball joint to knuckle nut Knuckle to strut assembly nut
60 ~ 72 (600 ~ 720, 44 ~ 53) 130 ~ 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 B.J.95+D.O.J.95 Type driveshaft (For 2.0L M/T) CENTOPLEX 278M/136K CASMOLY BJ ROLLUBE BJ Sunlight SW-2 AMBLYGON TA 10/2A CASMOLY DOJ DURALUBE DOJ Variant S-R2 Joint :60 3gr. Boot : 55 3gr. Recommended Quantity
B.J. boot grease
D.O.J. boot grease
Joint :60 3gr. Boot : 40 3gr.
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B.J.92+T.J.92 Type driveshaft (For 2.0L A/T) CENTOPLEX 278M/136K CASMOLY TJ ROLLUBE TJ Sunlight SW-2 KLK TJ 41-182 CASMOLY TJ ROLLUBE TJ Oneluber TJ Joint :60 3gr. Boot : 55 3gr.
B.J. boot grease
T.J. boot grease
Joint : 100 3gr. Boot : 45 3gr.
Drive Shaft & Axle > General > SPECIAL TOOLS SPECIAL TOOLS
Tool (Number and Name) 09495-33000 Puller Illustration Use 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 bridge
a. 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) Measurement of front wheel bearing pre-load. (Use with 09517-21500)
09532-11600 Preload socket
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 Maximum permissible joint angle B.J. D.O.J. T.J. Hub end play mm(in.) Wheel bearing starting torque Nm (kgcm, lbft) B. J. : Birfield Joint D.O.J. : Double Offset Joint T. J. : Tripod Joint M/T: Manual Transaxle A/T : Automatic Transaxle 2.0L M/T B.J. 95 D.O.J. 95 2.0L A/T B.J. 92 T.J. 92
46or more 22or more 0.008 (0.0003) or less 1.8 (18, 1.33) or less
45.8or more 23or more
Drive Shaft & Axle > General > TIGHTENING TORQUE TIGHTENING TORQUE
Nm Castle nut Knuckle to strut assembly nut Lower arm ball joint to knuckle nut Tie rod end to knuckle Brake caliper to knuckle Wheel nut Rear hub bearing flange nut Rear brake to rear axle carrier mounting bolt 200 ~ 260 130 ~ 150 60 ~ 72 24 ~ 34 69 ~ 85 90 ~ 110 200 ~ 260 65 ~ 75 Kgcm 2000 ~ 2600 1300 ~ 1300 600 ~ 720 240 ~ 340 690 ~ 850 900 ~ 1100 2000 ~ 2600 650 ~ 750 lbft 148 ~ 192 96 ~ 111 44 ~ 53 18 ~ 25 51 ~ 63 66 ~ 81 148 ~ 192 48 ~ 55
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Rear strut to carrier nut Trailing arm to rear axle carrier mounting nut Rear suspension arm to rear axle carrier mounting nut Brake disc to hub Replace self-locking nuts with new ones after removal.
110 ~ 130 100 ~ 120 160 ~ 180 5~6
1100 ~ 1300 1000 ~ 1200 1600 ~ 1800 50 ~ 60
81 ~ 96 74 ~ 89 118 ~ 133 3.7 ~ 4.4
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 Vehicle pulls to one side Possible cause Galling of drive shaft ball joint Wear, rattle or galling of wheel bearing Defective front suspension and steering Vibration Wear, damage or bending of drive shaft Drive shaft rattle and hub serration Wear, rattle or sintering of wheel bearing Shimmy Improper wheel balance Defective front suspension and steering Excessive noise Wear, damage or bending of drive shaft Drive shaft rattle and hub serration Drive shaft rattle and side gear serration Wear, rattle or galling of wheel bearing Loose hub nut Defective front suspension and steering Remedy Replace Replace Adjust or replace Replace Replace Replace Adjust or replace Adjust or replace Replace Replace Replace Replace Adjust or replace Adjust or replace

Hyundai Elantra Drive Shaft Inspection and Repair Guide

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Hyundai Elantra Drive Shaft Inspection and Repair Guide

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11/15/13

11. Install the wheel and tire.

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

2. Remove the snap ring.

3. Install the Special Tools as illustrated.

60 ~ 72 (600 ~ 720, 44 ~ 53) 130 ~ 150 (1300 ~ 1500, 96 ~ 111)

Drive Shaft & Axle > General > LUBRICANTS LUBRICANTS

B.J. boot grease

D.O.J. boot grease

Joint :60 3gr. Boot : 40 3gr.

B.J. boot grease

T.J. boot grease

Joint : 100 3gr. Boot : 45 3gr.

09495-33100 Center bearing remover and installer

09517-21500 Front hub remover and installer

09517-29000 Knuckle arm bridge

09532-11600 Preload socket

09532-31200A Oil seal installer

Installation of wheel bearing to the knuckle.

09568-34000 Ball joint puller

Drive Shaft & Axle > General > SPECIFICATIONS SPECIFICATIONS

45.8or more 23or more

110 ~ 130 100 ~ 120 160 ~ 180 5~6

1100 ~ 1300 1000 ~ 1200 1600 ~ 1800 50 ~ 60

81 ~ 96 74 ~ 89 118 ~ 133 3.7 ~ 4.4

3. Install the hub cap.

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