Campaign SA011 - M/T Driveshaft Housing/Seal Inspection

Model Forte [TD]

Group Driveshaft and Axle(31)

Number KT2009101603

Date Friday, October 16, 2009

Area N. America

Subject
Service Action: Driveshaft Housing and Transaxle Oil
Seal Inspection and Replacement (SA011) (TRANS - 026)

- Description








This Service Action provides information related to 2010 Forte (TD) produced from 2/23/2009 ~ 8/12/2009 equipped with 6-speed manual transaxles. Some 2010 Forte vehicles may have interference with the inner tri-pod housing contacting with the axle seal cage. This bulletin describes the proper service procedure for replacing the inner tri-pod housing on both left and right side axle assemblies. Follow these instructions as some left and right hand replacement components are different in size and length.

- Effective Vehicle Information

AFFECTED PRODUCTION RANGE:

2010 Forte (TD) vehicles produced from 2/23/2009~8/12/2009.

- Parts Information





PARTS INFORMATION

- Service Procedure





1. Safely support the vehicle and remove the left front wheel and tire assembly as shown.





2. Remove the stabilizer link to strut assembly retaining nut so the strut assembly can pivot for access to remove the axle joint.





3. Disconnect the outer tie-rod end from the knuckle assembly as required.





4. Un-stake the axle nut using tapered punch. This will prevent the axle nut threads from getting damaged during removal. Remove and discard the retaining nut, do not reuse.





5. Remove the two (2) lower ball joint to knuckle retaining bolts and grease shield.





6. The axle assembly is ready to be removed from the transaxle using a long pry bar.





7. Shown is the preferred area to remove the axle joint, pop the axle joint out and away from the transaxle. A spring clip is used to retain the inner CV joint to the splined gear.





8. Inspect the oil seal carefully for interference and contact. If contact has occurred replace the axle seal using a seal remover tool as shown.





9. Using SST 09431-39000 Seal installer with 09500-11000 handle, position the left side axle seal on the tool and drive the seal into the transaxle case as shown. Make sure the seal is installed flush with the transaxle case. Clean off any fluid that spilled out down the side of the transaxle case.





10. Clamp the axle joint into the vise to stabilize the assembly for inner tri-pod housing replacement. Remove the outer band clamp using SST 09495-39100. Remove and discard the inner tri-pod housing.





11. Using the supplied grease, use half the container of grease to lubricate the new inner tripod joint housing and transfer the remaining grease from old housing into the replacement inner tri-pod housing.





12. Install the new replacement inner tri-pod housing (larger diameter housing, left side) to the inner tri-pod as shown in photo.





13. After installing the boot assembly, clean the excess grease from the CV joint assembly.





14. Install the band clamp using SST 09495-39100 to secure into position.





15. Install a new spring clip onto the end of the inner CV joint splines. The axle assembly is ready to be installed into the transaxle assembly.





16. Install the axle assembly with a quick push into the transaxle to seat the spring clip. Be careful not to damage the axle seal during installation of the axle shaft.

17. Insert the outer CV joint into hub/bearing and ensure correct spline alignment.

18. Tighten the following retainers as specified:

^ Ball joint/shield bolts to 72~87 lbs. ft. (97~117 Nm).

^ Strut link retaining nut to 72~87 lbs. ft. (97~117 Nm).

^ Tie-rod end castle nut to 17~25 lbs. ft. (23~33 Nm) and install new cotter pin.

^ Axle nut to 144~202 lbs. ft. (195~273 Nm), stake nut when torque is complete.

19. Install the tire and wheel assembly and torque to 65~80 lbs.ft. (88~108 Nm).

20. Repeat this same procedure on the R/S axle assembly.

21. Check the fluid level in the transaxle, top-off any lost lubricant and road-test for proper operation.





WARRANTY CLAIM INFORMATION: