Hyundai Kona: Driveshaft Assembly / TJ Joint Repair procedures

Disassembly

•	Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.

•	The boot band should be replaced with a new one.

1.	Remove the front driveshaft. (Refer to Driveshaft Assembly - “Front Driveshaft”)

2.	Remove the housing circlip (B) from the driveshaft spline (A).

3.	Remove both boot bands from the TJ housing.

Remove the TJ housing (A).

•	Make alignment marks on spider roller assembly (A), joint case (B), and shaft spline (C) to aid reassembly.

5.	Remove the retainer ring (A) from the shaft.

6.	Remove the spider assembly (B) from the driveshaft (A) using the special tool (09495-33000).

7.	Clean the spider assembly.

Remove the TJ boot (A).

•	For reusing the boot (A), wrap tape (B) around the driveshaft splines (C) to protect the boot (A).

Inspection

1.	Check the spider assembly for roller rotation, wear or corrosion.

2.	Check the groove inside the joint case for wear or corrosion

3.	Check the TJ boots for damage and deterioration.

Reassembly

1.	Wrap tape around the driveshaft spline(TJ) to prevent damage to the boot.

2.	Using the alignment marks (D) made during disassembly as a guide, install the spider assembly (A) and retainer ring (B) on the driveshaft splines (C).

3.	Add specified grease to the joint boot as much as it was wiped away at inspection.

4.	Install the both boot band.

5.	Using the SST (09495-39100) and long nose pliers , secure the TJ boot bands.

6.	Install the front driveshaft. (Refer to Driveshaft Assembly - "Front Driveshaft")

7.	Check the front alignment. (Refer to Suspension System - "Front Alignment")

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