Kia Soul EV: Driveshaft Assembly / Front Driveshaft Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / Driveshaft and axle / Driveshaft Assembly / Front Driveshaft Repair procedures

Replacement
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 front hub.

Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

   
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
3.
Remove the driveshaft coking 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 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.

4.
Remove the tie rod end ball joint (C) from the knuckle by using the SST (09568-34000).
(1)
Remove the split pin (A).
(2)
Remove the castle nut (B).
(3)
Use the SST (09568-34000).

Tightening torque:
23.5 ~ 33.3N.m (2.4 ~ 3.4kgf.m, 19.4 ~ 24.6lb-ft)

   
When using SST, be sure not to damage the dust cover of lower arm ball joint.
Keep SST tied to the car because there is arisk of injury by dropping the SST duringremoval of the lower arm ball joint.
The peripheral parts may be damaged when removing the lower arm ball joint with a general tool such as lever, so be sure to use SST.
5.
Remove the lower arm (A) from the knuckle.

Tightening torque:
58.8 ~ 70.6 N.m (6.0 ~ 7.2 kgf.m, 43.4 ~ 52.1 lb-ft)

6.
Using a plastic hammer, disconnect driveshaft (A) from the axle hub (B).

7.
Insert a pry bar (A) between the transaxle case and joint case, and separate the drive shaft (B) from the transaxle case.

8.
Install in the reverse order of removal.
9.
Check the front alignment.
(Refer to Suspension System - "Front Alignment")
Inspection
1.
Check the driveshaft boots for damage and deterioration.
2.
Check the ball joint for wear and damage.
3.
Check the splines for wear and damage.
4.
Check the dynamic damper for cracks, wear and position.

5.
Check the driveshaft for cracks and abnormal wear.
Disassembly
   
Do not disassemble BJ assembly
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 BJ circlip (B) from the TJ housing (A).

3.
Remove both boot bands from the TJ housing.

4.
Pull out the boot from the transaxle side joint (TJ).
5.
While separating joint boot (A) of the transaxle side,wipe the grease in VTJ case (B) and lay them in the correct order.

   
Make alignment marks (D) on spider roller assembly (A), TJ housing (B), and shaft spline (C) to aid reassembly.

6.
Remove the snap ring (A) from the shaft.

7.
Remove the spider assembly (B) from the driveshaft (A) using the special tool (09495-33000).

8.
Clean the spider assembly.
9.
Remove the TJ boot (A).
   
For reusing the boot (A), wrap tape (B) around the driveshaft splines (C) to protect the boot (A).

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 snap ring (B) on the driveshaft splines (C).

3.
Add grease to the joint boot.
4.
Install both boot bands.
5.
To control the air in the TJ boot, keep the specified distance between the boot bands when they are tightened.
Motor
Distance (L) mm (in.)
LH side
RH side
80KW
546.3
804.7

6.
Using the SST(09495-3K000), secure the TJ boot bands.

Clearance (A): 2.0 mm (0.0787 in.) or less

7.
Install the Front Driveshaft.
(Refer to Driveshaft Assembly - "Front Driveshaft")
8.
Check the front alignment.
(Refer to Suspension System - "Front Alignment")
Front Driveshaft Components and Components Location
Component (1) 1. Driveshaft (RH) 2. Circlip3. Driveshaft (LH) Component (2) [LH] 1. BJ assembly 2. BJ circlip 3. BJ boot band 4. BJ boot 5. Shaft6. TJ boot band7. TJ boot8. Spider assemb ...

Front Axle Assembly
...

Other information:

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