Hyundai Kona: Driveshaft Assembly / Front Driveshaft Repair procedures

Removal
[Gamma 1.6 T-GDI, Nu 2.0 MPI]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from the front hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)
  
Be careful not to damage the hub bolts when removing the front wheel and tire (A).

3.
Remove the front brake caliper.
(Refer to Brake System - "Front Disc Brake")
4.
Loosen the driveshaft caulking nut (A).
Tightening torque :
274.6 - 294.2 N.m (28.0 - 30.0 kgf.m, 202.5 - 217.0 lb-ft)

  
The driveshaft lock nut (A) should be replaced with new ones.
After installation driveshaft lock nut, stake the lock nut using a chisel and hammer as shown in the illustration below.
Caulking depth : 1.5 mm (0.591 in.)

5.
Remove the tie rod end ball joint.
(1)
Remove the split pin (C).
(2)
Loosen the nut (B).
(3)
Using SST(09568-1S100), separate the ball joint (A) from the knuckle.
Tightening torque :
23.5 - 34.3 N.m (2.5 - 3.5 kgf.m, 18.1 - 25.3 lb-ft)

6.
Loosen the lower arm nut (A) and then remove the lower arm ball joint by using SST(09568-1S100).
Tightening torque :
58.8 - 70.6 N.m (6.0 - 7.2 kgf.m, 43.4 - 52.1 lb-ft)

  
Do not reuse the lower arm lock nut (A).
7.
Loosen the screw and then remove the front disc (A).
Tightening torque :
4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

8.
Remove the driveshaft (A) from the front axle assembly (B).

9.
Insert a pry bar (A) between the transaxle case and joint case, and separate the driver side driveshaft from the transaxle case.

  
Use a pry bar (A) being careful not to damage the transaxle and joint.
Do not insert the pry bar (A) too deep, as this may cause damage to the oil seal.
Do not pull the driveshaft by excessive force it may cause components inside the joint kit to dislodge resulting in a torn boot or a damaged bearing.
Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
Support the driveshaft properly.
Replace the retainer ring whenever the driveshaft is removed from the transaxle case.
10.
Loosen the inner shaft mounting bolts and then remove the passenger side driveshaft (A).
Tightening torque :
39.2 - 63.7 N.m (4.0 - 6.5 kgf.m, 28.9 - 47.0 lb-ft)

[Kappa 1.0 T-GDI]
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from the front hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)
  
Be careful not to damage the hub bolts when removing the front wheel and tire (A).

3.
Remove the front brake caliper.
(Refer to Brake System - "Front Disc Brake")
4.
Loosen the driveshaft caulking nut (A).
Tightening torque :
274.6 - 294.2 N.m (28.0 - 30.0 kgf.m, 202.5 - 217.0 lb-ft)

  
The driveshaft lock nut (A) should be replaced with new ones.
After installation driveshaft lock nut, stake the lock nut using a chisel and hammer as shown in the illustration below.
Caulking depth : 1.5 mm (0.591 in.)

5.
Remove the tie rod end ball joint.
(1)
Remove the split pin (C).
(2)
Loosen the nut (B).
(3)
Using SST(09568-1S100), separate the ball joint (A) from the knuckle.
Tightening torque :
23.5 - 34.3 N.m (2.5 - 3.5 kgf.m, 18.1 - 25.3 lb-ft)

6.
Loosen the lower arm nut (A) and then remove the lower arm ball joint by using SST(09568-1S100).
Tightening torque :
58.8 - 70.6 N.m (6.0 - 7.2 kgf.m, 43.4 - 52.1 lb-ft)

  
Do not reuse the lower arm lock nut (A).
7.
Loosen the screw and then remove the front disc (A).
Tightening torque :
4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

8.
Remove the driveshaft (A) from the front axle assembly (B).

9.
Insert a pry bar (A) between the transaxle case and joint case, and separate the driver side driveshaft from the transaxle case.

  
Use a pry bar (A) being careful not to damage the transaxle and joint.
Do not insert the pry bar (A) too deep, as this may cause damage to the oil seal.
Do not pull the driveshaft by excessive force it may cause components inside the joint kit to dislodge resulting in a torn boot or a damaged bearing.
Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
Support the driveshaft properly.
Replace the retainer ring whenever the driveshaft is removed from the transaxle case.
10.
Insert a pry bar (A) between the clutch housing and joint case, and separate the passenger side driveshaft from the clutch housing.

Installation
1.
Install in the reverse order of removal.
2.
Check the alignment.
(Refer to Suspension System - "Alingment")
Front Driveshaft Components and components location
Components [Kappa 1.0 T-GDI] 1. Driveshaft (LH) 2. Dynamic damper 3. Driveshaft (RH) [GAMMA 1.6 T-GDI, Nu 2.0 MPI] 1. Drivesh ...

TJ Joint Components and components location
Components (1) [Gamma 1.6 T-GDI, Nu 2.0 MPI] 1. BJ assembly 2. BJ circlip 3. BJ boot band 4. BJ boot 5. Dynamic damper band 6. Dynamic damper 7. ...

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