Drivetrain - Front Drive Axle Snapping Noise

Group: CHASSIS

Number: 06-50-009

Date: AUGUST, 2006 Model

Model: SONATA, AZERA

Subject
FRONT HUB AND DRIVESHAFT ISOLATION WASHER
INSTALLATION PROCEDURE

DESCRIPTION:

This bulletin provides a procedure to insert a washer between the front hub and driveshaft.

^ Symptom/Condition:

A "snap" noise caused by surface contact between the front hub and driveshaft may be heard when some SONATA (NF) or AZERA (IC) vehicles are driven forward after being driven in reverse.





^ Cause:

Slip along the contact surface between the front hub and the driveshaft.

^ Service Procedure: Insert the isolation washer between the front hub and driveshaft.

NOTE:
Do not use this procedure to service or repair other sources of noise.

VEHICLES AFFECTED:

^ Model: SONATA (NF), AZERA(TG)

^ Affected vehicle production date range: From start of production





PARTS REQUIRED:

1. Lift the vehicle off the ground and remove a front wheel and tire assembly.





2. Remove the split pin (B) from the front hub (C) and remove the driveshaft castle nut (A).

Driveshaft castle nut torque: 20~28kgf-m (148~207lb-ft)





3. Remove the split pin and the nut holding the tie rod end (D) to the knuckle. Using the special tool (09568-4A000), disengage the tie rod end (D) from the knuckle. Tie rod end to knuckle nut torque: 2.4~3.4kgf-m (18~25lb-ft)





4. Remove the 2 bolts (E) and disengage the lower arm ball joint from the knuckle. Lower arm ball joint to knuckle nut torque: 10~12kgf-m (74~88 lb-ft)

5. Disengage the driveshaft from the front hub using a plastic hammer.





6. Remove any foreign material from the contact surface between the front hub (F) and the driveshaft (C) and then wipe it gently with a clean cloth.





7. Clean the isolation washer and apply grease to 2 points on one surface of the washer as shown in the photo.

[NOTE]
Be careful not to apply an excessive amount of grease. The grease is used to prevent the washer from moving freely during installation of the driveshaft to the front hub.





8. Center the washer on the front hub with its greased surface facing the front hub and apply it to the front hub.

[NOTE]
The washer can be applied to the driveshaft as well as the front hub.

9. Repeat steps 1 through 8 on the other side and install all the removed parts in reverse order of removal.

[NOTE]
When installing the driveshaft to the front hub, be careful not to allow the washer to move.





WARRANTY INFORMATION: