Hyundai i20 Quiz
Drive Shaft and Axle

FRONT DRIVE SHAFT Repair Procedures

In this manual: Drive Shaft and Axle
General Information — 17Engine Mechanical System — 79Engine Electrical System — 50Emission Control System — 22Engine/Fuel Control System — 107Clutch System — 27MANUAL TRANSMISSION SYSTEM — 21Drive Shaft and Axle — 18Suspension System — 29Steering System — 21Restraint — 41Braking System — 53Body Work (Interior and Exterior) — 190Body Electrical System — 181Heating, Ventilation and Air Conditioning — 58
31steps
~191min
5/5difficulty
1special tools
04080120160200127.594N·mlb·ft
Tightening torque found on this page
Done 0 of 31

DEPOSIT

  1. Loosen the wheel nuts slightly. Raise the vehicle and make sure it is securely supported.
  2. Remove the front wheel and tire assembly from the hub.

    Tightening torque: 107.9 - 128 N·m

  3. Loosen the hub nut (A).

    Tightening torque: 274.6 ~ 294 N·m (28.0 ~ 30.0 kgf·m, 202.5 ~ 217.1 lbf·ft)

  4. Remove the stabilizer bar link (B) from the crossmember assembly by loosening the nut (A).

    Tightening torque: 98.1 ~ 118 N·m

  5. Remove the cotter pin and loosen the castellated nut (A).

    Tightening torque: 23.5 ~ 33 N·m

  6. Separate the ball joint from the tie rod end using SST (09568-1C100).
  7. Loosen the nut (A) and separate the ball joint from the lower arm.

    Tightening torque: 58.8 ~ 71 N·m

  8. Disconnect the drive shaft (A) from the front hub assembly.
  9. Insert a lever (A) between the transaxle case and the seal housing (B), and separate the drive shaft from the transaxle.
  10. To install, perform the removal procedure in reverse order.

Inspection

  1. Check that the drive shaft boots are not damaged or deteriorated.
  2. Check the drive shaft splines for wear or damage.

DISASSEMBLY

  1. Remove the snap ring (B) from the spline of the drive shaft (A).
  2. Remove the two bellows seal clamps from the transaxle side seal housing. (TJ)
  3. Remove the bellows seal from the gear side seal (B).
  4. When separating the bellows from the bellows joint (A) on the transmission side, remove the grease from the housing (B) and separate the two parts.
  5. Remove the snap ring (A) and roller cross (B) from the shaft.
  6. Disconnect the cross assembly (B) from the drive shaft (A) using the special service tool (09495-33000).
  7. Clean the entire cross assembly.
  8. Remove the bellows (A) from the bellows joint (TJ) on the transaxle side.
  9. Using pliers or a flat-tip screwdriver (-), remove the dynamic damper clamps (B) (A).
  10. Secure the drive shaft (A) in a vise (B) as shown in the illustration.
  11. Apply powder soap to the shaft to prevent damage to the part between the shaft spline and the dynamic damper when removing the dynamic damper.
  12. Carefully separate the dynamic damper (A) from the shaft (B).

Installation

  1. Wrap insulation tape around all splines of the drive shaft (TJ) to avoid damaging the dust covers.
  2. Apply grease to the wheel-side bellows seals, then install the bellows.
  3. Install the caliper.
  4. Install the boots and bellows seal on the transaxle side.
  5. Using the alignment marks (D) made during disassembly to facilitate installation, install the cross assembly (A) and elastic ring (B) onto the splines of the transmission shaft (C).
  6. Add the specified grease to the bellows in the amount removed for inspection.
  7. Install two sealing bands.

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