Kia_Sephia_Rio_Spectra_Optima_1998-2006

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the wheel and tire assemblies.
  4.  
  5. Remove the splash shield, if equipped.
  6.  
  7. Drain the transaxle.
  8.  
  9. Raise the staked portion of the hub locknut with a hammer and chisel. Lock the hub by applying the brakes and loosen the nut.
  10.  
  11. Separate the stabilizer bar from the lower control arm.
  12.  
  13. Remove the cotter pin and nut from the tie rod end ball stud.
  14.  
  15. Remove the tie rod end from the knuckle, using a suitable tool.
  16.  
  17. Remove the lower ball joint pinch bolt and nut.
  18.  
  19. Separate the ball joint from the knuckle, using a prybar on the control arm.
  20.  
  21. Position a prybar between the inner CV-joint and transaxle case. Carefully pry the halfshaft from the transaxle being careful not damage the oil seal. If equipped with a right side intermediate shaft, insert the prybar between the halfshaft and intermediate shaft and tap on the bar to uncouple them.
  22.  
  23. Remove the hub locknut and discard.
  24.  
  25. Pull outward on the hub/knuckle assembly, push the outer CV-joint stub shaft through the hub, and remove the halfshaft. If the halfshaft is stuck in the hub, install the old hub nut to protect the stub shaft threads. Tap on the nut, using only a soft mallet, to remove the halfshaft.
    NOTE
    Install Differential Side Gear holder K49A-4208-AT, into the transaxle after removing the halfshaft, to keep the differential side gear in position. If the gear becomes out of position the differential may have to be removed to realign the gear.

  26.  
  27. Remove the intermediate shaft, if necessary, by removing the support bearing bolts and pulling the shaft from the transaxle.

    Click image to see an enlarged view

    Fig. Exploded view of the halfshafts and related components

  28.  

To install:

Click image to see an enlarged view

Fig. Support bearing bolt tightening sequence

  1. Install a new circlip on the end of the intermediate shaft,
    1. 1.5L, 1.6L (VIN 5), 1.8L install the circlip with the end gap facing upward.
    2.  
    3. 1.6L (VIN 3), 2.0L, 2.4L and 2.7L install the circlip with end gap facing downward.
    4.  

  2.  
  3. Install the intermediate shaft in the transaxle, being careful not to damage the oil seals.
  4.  
  5. Install the support bearing bolts and tighten, in sequence, to 45 ft. lbs. (61 Nm).
  6.  
  7. Install a new circlip on the end of the halfshaft, with the end gap facing upward.
  8.  
  9. Install the halfshaft into the transaxle, being careful not to damage the oil seal.
  10.  
  11. Install the halfshaft into the intermediate shaft, if equipped.
  12.  
  13. Install the other end of the halfshaft through the hub. Loosely install a new locknut.
  14.  
  15. Install the lower ball joint into the knuckle.
  16.  
  17. Install the pinch bolt and nut and tighten to 40 ft. lbs. (54 Nm).
  18.  
  19. Install the tie rod end to the steering knuckle and tighten the nut to 42 ft. lbs. (57 Nm). Install a new cotter pin. Tighten the nut, if necessary, to align the ball stud hole with the nut castellation.
  20.  
  21. Install the stabilizer bar to the lower control arm.
  22.  
  23. Install the splash shield and the wheel and tire assemblies.
  24.  
  25. Lock the hub with the brakes. Tighten the new hub nut to 155-206 ft. lbs. (214-279 Nm). After tightening, stake the locknut using a hammer and dull bladed chisel.
  26.  
  27. Fill the transaxle with the proper type and quantity of fluid.
  28.  

 
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