Kia_Sephia_Rio_Spectra_Optima_1998-2006

Overhaul

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1.5L, 1.6L (VIN 5) And 1.8L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft.
  4.  
  5. Pry up the locking clip of the transaxle side boot retaining band with a suitable tool.
  6.  
  7. Using a pair of pliers, remove the retaining band.
  8.  
  9. Slide the boot away to access the CV-joint.
  10.  
  11. Matchmark the CV-joint housing and the shaft to ensure proper positioning during assembly.
  12.  
  13. Remove the outer ring.
  14.  
  15. Matchmark the shaft and tripod assembly to ensure proper positioning during assembly.
  16.  
  17. Remove the snapring.
    NOTE
    Be careful not to damage the needle bearings.

  18.  
  19. Using a brass drift and a hammer, drive the tripod joint from the shaft.
    NOTE
    Cover the halfshaft serration-s with tape, so as not to damage the boot.

  20.  
  21. Slide the boot off the shaft.
    NOTE
    It is not necessary to remove the dynamic damper from the shaft unless replacement or repair is required.

  22.  
  23. Pry up the locking clip of the dynamic damper retaining band with a suitable tool.
  24.  
  25. Using a pair of pliers, remove the retaining band.
  26.  
  27. Remove the dynamic damper.
    NOTE
    Do not remove the outer boot from the shaft unless it is necessary.

  28.  
  29. Pry up the locking clip of the outer boots small and large retaining bands with a suitable tool.
  30.  
  31. Using a pair of pliers, remove the retaining bands.
  32.  
  33. Cover the halfshaft serration-s with tape and remove the boot.
  34.  

To install:


NOTE
The boot on the wheel side of the driveshaft is larger than the boot on the differential side.



Click image to see an enlarged view

Fig. Measure the boots as shown to ensure the larger boot is placed on the wheel side of the halfshaft.

  1. Cover the halfshaft serration-s with tape and install the inner boot.
    NOTE
    The bands should be installed so that their pointed ends initially point in the forward direction of rotation.

  2.  
  3. Install the dynamic damper and band. Fold the band back by pulling on the end of it with a pair of pliers, then lock the end of the band by bending the locking clip.
  4.  
  5. Install the outer boot.
  6.  
  7. Align the marks made during removal and install the tripod joint using a brass drift and a hammer.
  8.  
  9. Install the snapring.
  10.  
  11. Apply the grease supplied with the joint rebuild kit to the tripod joint, outer ring and the boot.
  12.  
  13. Install the outer ring.
  14.  
  15. If the outer boot was removed, fill it with the correct amount of grease as follows:
    1. Transaxle side: 4.94 oz. (140g).
    2.  
    3. Wheel side: 4.58 oz. (130g).
    4.  

  16.  
  17. Make sure the boots are not damaged, then carefully up the small end of the boots to release any trapped air.
  18.  
  19. Measure the length of the driveshaft to ensure it is the correct length. Refer to the accompanying illustration for the driveshaft measuring points and the correct specifications.

    Click image to see an enlarged view

    Fig. Make sure the driveshaft-s specified length is correct

  20.  
  21. Install the boot retaining bands. Fold the bands back by pulling on the ends with a pair of pliers, then lock the end of the bands by bending the locking clips.
  22.  
  23. Install the halfshaft.
  24.  

1.6L (VIN 3), 2.0L And 2.4L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft and place into a vise.
  4.  
  5. Remove the circlip from the splines of the transaxle side Tripot Joint (TJ) case.
  6.  
  7. Remove both boot clamps from the transaxle side TJ case.
  8.  
  9. Pull off the outer TJ boot.
  10.  
  11. Matchmark the trunion assembly to the TJ case and halfshaft spline.

    Click image to see an enlarged view

    Fig. Mark the joint assembly as shown-TJ-BJ type

  12.  
  13. Remove the circlip from the splines of the spider assembly side.
  14.  
  15. Using Special Tool 09495-33000, remove the spider assembly from the halfshaft.

    Click image to see an enlarged view

    Fig. Using special tool 09495-33000 to remove the spider assembly

  16.  
  17. Remove the inner TJ boot.
  18.  
  19. Remove the dynamic damper clamps.
  20.  
  21. Separate the dynamic damper from the halfshaft, being careful not to damage the shaft splines.
  22.  
  23. Remove the Birfield Joint (BJ) boot clamp.
  24.  
  25. Remove the BJ being careful not to damage the boot.
  26.  

To install:


NOTE
Wrap tape around the axle shaft splines to prevent damage to the boots during assembly.


NOTE
Use new circlips and boot clamps for assembly.

  1. Apply grease to the halfshaft and install the BJ, boots and clamps.
  2.  
  3. Install the dynamic damper, keep the halfshaft straight and tighten the dynamic band.
  4.  
  5. Install the inner TJ boot and band.
  6.  
  7. Install the trunion assembly and circlip, aligning the matchmarks with each other.
  8.  
  9. Add the specified grease to the TJ, replaced all that was wiped away.
  10.  
  11. Install the outer TJ boot and clamp.
  12.  
  13. Install the halfshaft.
  14.  

2.7L Engine



With Automatic Transaxle
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft and place into a vise.
  4.  
  5. Cut to remove the Glaenzer Interior (GI) and Angular Contact (AC) big clamps.
  6.  
  7. Using a brass drift and hammer, remove the GI and AC small clamps.
  8.  
  9. Matchmark the tripod and tulip assemblies to the halfshaft.

    Click image to see an enlarged view

    Fig. Matchmarks on the tripod and tulip assemblies

  10.  
  11. Remove the tulip assembly from the halfshaft.
  12.  
  13. Using a snap ring expander, remove the circlip from the tripod.
  14.  
  15. Matchmark the tripod and joint shaft.

    Click image to see an enlarged view

    Fig. Matchmark the tripod and joint shaft

  16.  
  17. Using a brass drift and hammer, remove the tripod from the joint shaft.
  18.  
  19. Place tape over the splines of the shaft (GI side) and remove the AC boot clamps.
  20.  
  21. Pull out the GI and AC boots.
  22.  

To install:

  1. Ensure there is tape over the splines of the shaft to prevent damage to the boots when installing.
  2.  
  3. Using new boots, place new clamps to the small boot ends and install them onto the halfshaft.
  4.  
  5. Align the matchmarks and place the beveled side of the tripod axial splines toward the AC joint. Using a suitable tool and hammer, tap the tripod onto the halfshaft.

    Click image to see an enlarged view

    Fig. Tap the tripod onto the halfshaft

  6.  
  7. Install a new circlip.
  8.  
  9. Fill the AC and GI boot with the specified grease to replace any that was removed during disassembly.
  10.  
  11. Align the matchmarks and install the GI joint to the shaft.
  12.  
  13. Install the boot clamps, ensuring that the boots are properly seated on the halfshaft grooves.
  14.  
  15. Secure the large boot clamps to the specified distance of .079 inches (2 mm) as shown.

    Click image to see an enlarged view

    Fig. Closing the large boot clamps to the specified distance

  16.  
  17. Secure the small clamps to the specified distance of 0.071 inches (1.8 mm) as shown.

    Click image to see an enlarged view

    Fig. Closing the small boot clamps to the specified distance

  18.  
  19. Install the halfshaft into the vehicle.
  20.  

With Manual Transaxle
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft and place into a vise.
  4.  
  5. Remove the Double Offset Joint (DOJ) boot bands.
  6.  
  7. Pull the DOJ boot from the outer race.
  8.  
  9. Remove the circlip from the DOJ and pull the halfshaft from the outer race.
  10.  
  11. Remove the snap ring and take out the inner race assembly.
  12.  
  13. Remove the Birfield Joint (BJ) boot bands.
  14.  
  15. Pull out the DOJ boot and BJ boot.
    NOTE
    If the boots are to be reused, wrap tape around the halfshaft splines.

  16.  

To install:


NOTE
Use new circlips and boot clamps for assembly.

  1. Apply some boot grease to the halfshaft and install the boots.
  2.  
  3. Apply the specified kit grease to the inner race and cage.
  4.  
  5. Install the cage so that it is offset on the inner race as shown.

    Click image to see an enlarged view

    Fig. Install the cage so that it is offset on the race

  6.  
  7. Apply the specified grease to the cage and fit the balls into the cage.
  8.  
  9. Position the chamfered side as shown. Install the inner race on the halfshaft and install the snap ring.

    Click image to see an enlarged view

    Fig. Install the chamfered side of the cage as shown

  10.  
  11. Apply the specified grease to the BJ outer race and install the outer race onto the halfshaft.
  12.  
  13. Apply the specified grease into the DOJ boot and install the boot onto the halfshaft.
  14.  
  15. Tighten the DOJ boot bands.
  16.  
  17. Add the specified grease to the BJ to replace what was wiped away.
  18.  
  19. Install the boots and tighten the BJ boot bands.
  20.  
  21. Install the halfshaft.
  22.  

 
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