Hyundai Kona: Coupling Assembly / Direct Electro Hydraulic Actuator Coupling Repair procedures

Hyundai Kona (OS) 2018-2025 Service Manual / 4 Wheel Drive (4WD) System / Coupling Assembly / Direct Electro Hydraulic Actuator Coupling Repair procedures

Inspection

•	All units are filled up with coupling fluid (ultra-low viscosity ATF) prior to shipping. Inspection, fill-up, and replacement of coupling fluid is therefore not necessary (zero maintenance, lifetime fluid).

Removal

Remove the 4WD coupling assembly bolts (A-3ea) mounted to the rear propeller shaft (B).

Tightening torque :

49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.1 - 47.0 lb-ft)

2.	Using a flat tool, separate the propellar shaft from 4WD coupling assembly.

3.	Disconnect the pressure sensor connector (A) and Oil hydraulic motor connector (B).

4.	Loosen the coupling assembly mounting bolts (A-4ea).

Separate the 4WD coupling assembly (B) from the rear differential assembly using a rigid rod.

Tightening torque :

58.8 - 63.7 N.m (6.0 - 6.5kgf.m, 43.3 - 47.0lb-ft)

Coupling Maintenance Precautions

Maintain the coupling at a horizontal level.

•	Refer to the handling caution level (A) when servicing the coupling (removal, installation, replacement, etc.).

•	Always maintain a horizontal posture.

Installation

To install, reverse the removal procedure.

•	Smear the splines (A) with molybdenum type high pressure grease.

•	When install the coupling, be careful not to damage the oil seal (B).

2.	After replacing the coupling, reset the 4WD ECU's clutch learing using the GDS tool. (Refer to 4WD Control System - "Repair procedure")

Direct Electro Hydraulic Actuator Coupling Description and operation

Description 4WD ECU processes signals from various sensors and determines the current road and driving conditions. The ECU then utilizes this information to implement precision ...

Oil hydraulic Motor(Actuator) Description and operation

Description The 4WD ECM controls the Pump Motor Pump (Actuator) to generating an oil pressure. The pressure engages a multiple disk clutch to transfer torque to the rear wheels. ...

Other information:

Hyundai Kona (OS) 2018-2025 Service Manual: Rear Differential Carrier Repair procedures
Removal 1. Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported. 2. Remove the rear wheel and tire (A) from rear hub. Tightening torque : 107.9 - 127.5 N. ...

Hyundai Kona (OS) 2018-2025 Owners Manual: ISG system malfunction
The ISG system may not operate: When there is a malfunction with the ISG sensors or the ISG system. The followings occur, when there is a malfunction with the ISG system: The auto stop indicator () will blink in yellow on the instrument cluster. The light on the ISG OFF button will illuminate. ...