Body/Frame - Subframe Bushing Replacement
Model: Sportage [KM]Group: Suspension System(21)
Number: KT2009110302
Date: Tuesday, November 03, 2009
Area: N. America
Subject
Procedure for Using Kias New Subframe Bushing
Remover and Installer for Sportage (KM) (SST - 019)
- Description
This Technical Service Bulletin provides instructions for using the bushing remover and installer. Tool bushings can be removed
and installed without removing the sub frame from the vehicle. The subframe will be lowered to access the top of the bushing
and provide space for the tool.
The repair procedure consist of 4 main operations:
1. Removing The Subframe Bushing
2. Removing The Outer Sleeve
3. Inspecting Subframe
4. Installing the New Subframe Bushing
- Effective Vehicle Information
AFFECTED PRODUCTION RANGE:
All 2005 ~ 2010 Sportage (KM)
- Service Procedure
Service Procedure Lowering the Subframe to Replace the Rear Bushings
1. Pull back the carpet and remove the bolt that holds the U-Joint on the steering rack.
2. Lift up the U-Joint far enough to mark the location on the spline.
3. Install a steering wheel holder.
4. Lift the joint off the shaft.
5. 2.0L Engine, remove the large bolt going through the rear
mount.
6. 2.7L Engine, loosen the clamp holding the intake tube to the Air Filter Box. Disconnect the harness from the Air Flow Meter.
Remove the bolts and lift out the Air Filter Box.
Next remove the 3 bolts holding the mount to the transaxle.
7. 2.7L Engine, remove the 2 bolts and 2 nuts holding the mount bracket between the engine and mount.
You may need to place a floor jack under the front of the engine before removing the bolts.
Carefully lower the floor jack.
8. Remove the bolts and screws holding the Skid Plate and remove the Skid Plate.
9. Support the front of the subframe with a screw jack.
10. Loosen the front subframe bolts about 1/4 to 3/8 of an inch.
11. Lower the Screw Jack allowing the subframe to set on the lowered bolts.
12. On the rear of the subframe, remove the 2 bolts and 1 nut holding the Corner Stays. Remove the Corner Stays.
13. Place a Screw Jack under the rear of the subframe.
14. Remove the 2 bolts holding the rear of the subframe to the
vehicle.
15. With the Screw Jack, lower the rear of the subframe to get at
least 1 inch of clearance between the subframe and the body peg.
Remove the Upper Stopper.
Proceed to Removing The Subframe Bushing procedure.
Afterwards, if replacing the front bushings, loosely install rear
bushing bolts and remove corner stays and front bushing bolts.
Service Procedure Removing The Subframe Bushing
The Kia Subframe Bushing Remover and Installer will need to
be configured according to the illustration for Removing The
Subframe Bushing.
1. Locate the 2 tabs on the bushing's flange and mark the
locations on the subframe.
2. Lift the assembly into place placing the rod through the
center of the bushing. Thread the nut on the top of the threaded
rod.
Line up the slots in the Installer/Remover Cup with the tabs on
the bushing. This will allow the cup to fit squarely over the
bushing.
Make sure the tool sets squarely around the bushing flange and
on the subframe.
Hand tighten the nuts until the assembly is held in place.
3. Using hand tools, tighten the lower nut to remove the bushing.
If the bushing does not begin moving after applying pressure, tap the side of the subframe with a hammer.
If the rubber separates from the outer sleeve, continue removal with the procedure below under "Removing Outer Sleeve"
Otherwise, skip the next section and continue to the "Install New Subframe Bushing" instructions.
Service Procedure Removing The Outer Sleeve
The Kia Subframe Bushing Remover and Installer will need to be configured according to the illustration for Removing The Outer Sleeve.
1. After any rust has been removed from the inside of the sleeve, place the Outer Sleeve Remover into the sleeve.
2. While holding the Outer Sleeve Remover completely into the sleeve, tighten the top nut of the adaptor.
Tighten only enough to hold the jaws firmly against to inside of
the sleeve. Do not over tighten.
3. Align the slots in the Installer/Remover Cup with the tabs on
the bushings. This will allow the cup to fit squarely over the bushing shell.
4. Make sure the Installer/Remover Cup sets squarely around the bushing flange and on the subframe. Hand tighten the nuts until the assembly is held in place.
5. Using hand tools, tighten the lower nut to pull the sleeve from
the sub-frame.
If the sleeve does not begin moving after applying pressure, tap
the side of the subframe with a hammer.
Service Procedure Inspecting Subframe
1. After the subframe bushing's outer sleeve has been removed
from the subframe, inspect the bushing housing area for a gap
between the upper and lower subframe layers.
If there is more than a 1.0 mm gap between the upper and lower
subframe layers at the top of the bushing housing area, the
subframe must be replaced.
If there is a gap of 1.0 mm or less between the upper and lower
subframe panels at the bottom of the bushing housing area, the
subframe may be reused.
Service Procedure - Installing the New Subframe Bushing
The Kia Subframe Bushing Remover and Installer will need to
be configured according to the illustration to Install New
Subframe Bushing.
1. Place the bushing in the subframe with the tabs lined up with
the marks made on the subframe.
2. Assemble a nut on the end of the threaded rod along with the 2 washers and thrust washers.
Insert the threaded rod through the deep end of the Installer/Remover Cup, then through the new bushing and finally through the sub-frame and Installer Plate.
Thread the second nut on the top of the threaded rod.
3. Using hand tools, tighten the lower nut to press the bushing
into the subframe.
If the nut runs too far up the threaded rod, you can use the
Small Cup as a spacer.
4. Reinstall all removed components in the reverse order of
removal.
REQUIRED SPECIAL TOOLS
WARRANTY CLAIM INFORMATION:
Refer to the Kia LTS (2009 Q4) for Labor Operation numbers (62465R0A, 62465R0C, 62465R0D, 62465R00).