Hyundai Cars 2006-2008

With Manual Transaxle

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CV-Boots Inspection



  1. Check the Double Offset Joint (DOJ) outer race, inner race, cage and balls for rust or damage.
  2.  
  3. Check splines for wear.
  4.  
  5. Check for tears, water, foreign matter, or rust in the Birfield Joint (BJ) boot.
  6.  
  7. Check the DOJ boot for tears, cuts or holes.
    CAUTION
    When the Birfield Joint 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 Birfield Joint assembly and replace grease.

  8.  

Removal & Installation



1.6L, 2.0L, 2.4L & 2.7L Engines

Specific to:

Hyundai Accent 2006-2008

Hyundai Elantra 2006-2008

Hyundai Sonata 2006-2008

Hyundai Tiburon 2006-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the front wheel and tire from front hub.
  6.  
  7. Remove the front wheel speed sensor cable bracket mounting bolt.
    WARNING
    If the bracket mounting bolt is not removed, the front wheel speed sensor cable may be damaged.

  8.  
  9. Remove the split pin, then remove castle nut and washer from the front hub.
  10.  
  11. Remove the ball joint assembly mounting bolt from the knuckle.
  12.  
  13. Using a plastic hammer, disconnect halfshaft from the axle hub.
  14.  
  15. Insert a pry bar between the transaxle case and joint case, and separate the halfshaft from the transaxle case.
    WARNING
    Use a pry bar being careful not to damage the transaxle and joint. Do not insert the pry bar too deep, as this may cause damage to the oil seal. Do not pull the halfshaft by excessive force it may cause components inside the joint to dislodge resulting in a torn boot or a damaged bearing.

  16.  
  17. Pull out the halfshaft from the transaxle case.
    NOTE
    Plug the hole of the transaxle case with the oil seal cap to prevent contamination. Support the halfshaft properly. Replace the retainer ring whenever the halfshaft is removed from the transaxle case.

  18.  

To install:

  1. Apply gear oil on the oil seal contacting surface of transaxle case and the halfshaft splines.
  2.  
  3. Replace circlip with a new one.
    NOTE
    Be careful not to install a different kind of circlip, when replacing the circlip.

  4.  
  5. Before installing the halfshaft, set the opening side of the circlip facing downward.
  6.  
  7. After installation, check that the halfshaft cannot be removed by hand.
  8.  
  9. Install the halfshaft to the axle hub.
    WARNING
    Be careful to damage or dent the boots.

  10.  
  11. Install the ball joint assembly mounting bolt to the knuckle. Tightening torque: 72-87 ft. lbs. (98-118 Nm).
  12.  
  13. Install the washer, castle nut, and split pin to the front hub assembly. Tightening torque: 145-203 ft. lbs. (196-275 Nm).
    NOTE
    The washer should be assembled with convex surface outward when installing the castle nut and split pin.

  14.  
  15. Install the front wheel speed sensor cable bracket mounting bolt. Tightening torque: 61-96 inch lbs. (7-11 Nm).
  16.  
  17. Install the wheel and the tire to the front hub. Tightening torque: 65-80 ft. lbs. (88-108 Nm).

    Click image to see an enlarged view

    Fig. Exploded view of halfshaft components-1.6L, 2.0L, 2.4L, and 2.7L engines

  18.  

3.3L & 3.8L Engines

Specific to:

Hyundai Azera 2006-2008

Hyundai Sonata 2006-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Remove the split pin and halfshaft castle nut and washer from the front hub.
  6.  
  7. Using the special tool (09568-4A000), disconnect the tie rod end from the knuckle.

    Click image to see an enlarged view

    Fig. Using the special tool (09568-4A000), disconnect the tie rod end from the knuckle-3.3L & 3.8L engines

  8.  
  9. Remove the bolts and disconnect the knuckle from the lower arm assembly.
  10.  
  11. Disconnect the brake hose bracket from the knuckle.
  12.  
  13. Disconnect the wheel speed sensor bracket from the knuckle.
  14.  
  15. Using a plastic hammer, disconnect the halfshaft from the axle assembly.
  16.  
  17. Remove the left-hand halfshaft from the transaxle using a pry bar.
    WARNING
    Use a pry bar so you do not damage the joint. If you pull the halfshaft by excessive force, components inside the joint can be displaced causing the boot to be torn and the bearing to be damaged.

  18.  
  19. Plug the transaxle case opening with an oil seal cap in order to avoid contamination.
  20.  
  21. Support the halfshaft properly.
    NOTE
    Replace the retainer ring each time the halfshaft is removed from the transaxle case.


    WARNING
    While loosening the halfshaft nut, do not allow vehicle weight to be concentrated on the wheel bearing. If the vehicle moves, hold the wheel bearing using the special tool.

  22.  
  23. Remove the right-hand halfshaft.
    1. Remove the stabilizer link from the fork.
    2.  
    3. Remove the fork from the front lower arm.
      WARNING
      Be careful not to damage to the aluminum lower arm.

    4.  
    5. Remove the fork from the front strut assembly.
    6.  
    7. Remove the inner shaft cover from the inner shaft bracket.
    8.  
    9. Remove the inner shaft bracket mounting bolts.
    10.  
    11. Remove the front halfshaft assembly with the inner shaft from the transaxle.
      WARNING
      Do not try to disconnect the inner shaft from the halfshaft. Because they cannot be disconnected once assembled. Do not reuse the halfshaft which is disassembled from the inner shaft.

    12.  

  24.  
  25. Use the special tool (09432-11000), to remove the tone wheel.
  26.  

To install:

  1. Replace the circlips with new ones after removal.
  2.  
  3. Apply gear oil on the halfshaft splines and the contacting surface of differential case oil seal.
  4.  
  5. After installation, check that the halfshaft cannot be removed.
  6.  
  7. Install the right-hand halfshaft.
    1. Install the inner shaft bracket mounting bolt. Tightening Torque: 36-47 ft. lbs. (50-65 Nm).
    2.  
    3. Install the inner shaft cover by installing the cover mounting bolts. Tightening Torque: 84-120 inch lbs. (9-14 Nm).
    4.  
    5. Install the fork to the front strut assembly. Tightening Torque: 44-59 ft. lbs. (60-80 Nm).
    6.  
    7. Install the connecting bolt between the fork and the lower arm. Tightening Torque: 101-118 ft. lbs. (140-160 Nm).
    8.  
    9. Install the stabilizer link to the fork. Tightening Torque: 74-88 ft. lbs. (100-120 Nm).
    10.  

  8.  
  9. Install the halfshaft into the front axle assembly.
    WARNING
    Be careful not to damage the boot.

  10.  
  11. Install the knuckle in the lower arm assembly and tighten the bolts. Tightening Torque: 74-88 ft. lbs. (100-120 Nm).
  12.  
  13. Install the tie rod end in the knuckle. Tightening Torque: 18-25 ft. lbs. (24-34 Nm).
  14.  
  15. Install the wheel speed sensor in the knuckle.
  16.  
  17. Install the brake hose bracket to the front knuckle.
  18.  
  19. After installing the washer with convex surface outward, install the lock nut and the split pin. Tighten the lock nut to: 148-207 ft. lbs. (200-280 Nm).
  20.  
  21. Install the wheel & tire assembly.

    Click image to see an enlarged view

    Fig. Exploded view of halfshaft components-3.3L & 3.8L engines

  22.  

 
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