Campaign - R/H Axle Intermediate Shaft Noise
GROUP Service CampaignNUMBER SC 082B
MODEL 2011MY Sorento (XM) w/AWD
SUBJECT:
SERVICE CAMPAIGN: INTERMEDIATE SHAFT NOISE FOR AWD (SC028B0
*NOTICE;
This bulletin has been revised since SC082A was originally published. The repair procedure in this bulletin only applies to AWD Sorento (XM) vehicles.
This bulletin provides information related to some 2011 Sorento (XM) vehicles built from October 23, 2009 to May 22, 2010 with 2.4L engines and automatic transmissions. Although some customers might not have a direct complaint related to a clunk or squealing noise from the intermediate shaft Kia recommends that the AWD 2.4L engine vehicles with automatic transmissions be repaired for this concern. Kia is asking that dealers follow the procedure to grind the bracket and lubricate the intermediate shaft as outlined below.
Listed in this document is the AWD repair procedure Grind Bracket and Lubricate Intermediate Shaft Only.
*NOTICE
All vehicles potentially subject to this campaign should be verified to be not completed. WebDCS > Warranty Coverage > Warranty Coverage Inquiry > Check open Campaign Status.
*NOTICE
To improve customer satisfaction, always remember to refer to WebDCS Warranty Coverage (validation) Inquiry Screen (Service > Warranty Coverage > Warranty Coverage Inquiry) for a list of any additional campaigns or service actions that may need to be performed on the vehicle before returning it to the customer.
Repair Procedure:
1. Lift vehicle on hoist, remove lug nuts and remove the front right wheel.
Remove the splash guard in the fender well.
2. Remove the intermediate shaft heat shield.
3. Lift vehicle on hoist remove lug nuts and remove the front right wheel.
Remove the splash guard in the fender well.
Support caliper as required.
4. Remove front right wheel speed sensor.
5. Remove front right strut bolts.
6. Separate intermediate shaft from CV shaft.
7. Remove intermediate bracket mounting shaft bolts.
8. Remove AWD intermediate shaft.
Once the AWD intermediate shaft is removed the bearing bracket must be carefully ground to eliminate potential interference between the bearing bracket and the engine block.
*NOTICE
Image above is before grinding.
*NOTICE
Image above is after grinding
*NOTICE
The ground edges should be a minimum of 10mm by 3mm, as shown.
9. Use approximately 1.5 - 2.5 grams of grease.
Shown on teaspoon is proper amount of grease to use on right side splines.
10. After grinding the bearing bracket, remove any debris and clean the splines.
Lubricate splines with McLube MoS2-400 high temperature grease.
Use the image above as a reference for application of grease to the splines on AWD units.
11. Install the intermediate shaft and tighten bolts to 36-50 ft lbs. (48-67 Nm) then connect the CV joint to the intermediate shaft.
12. Inspect and confirm the intermediate shaft bracket is fully seated to engine block (No gap between engine block and bracket at bolting mounting point).
13. Confirm that the bracket is ground correctly by inserting a feeler gauge .001 between the engine block and intermediate shaft bracket. 'Zero' or no clearance (.001) should be found it bracket was ground correctly.
14. Install the Strut bolts, torque to 115-130 ft. Lbs. (155-176 Nm).
a) Install wheel speed sensor, torque to 60-96 inch lbs. (6.7-11 Nm).
b) Install brake caliper bolts, torque to 16-23 ft. lbs (21-31 Nm).
c) Install heat shield, torque to 72-108 inch lbs. (8-12 Nm).
d) Install splash shield and wheel assembly torque wheels to 65-79 ft. lbs. (88-107 Nm).
Repair is complete.
AFFECTED PRODUCTION RANGE
WARRANTY CLAIM INFORMATION
*NOTICE
To assure complete customer satisfaction, always remember to refer to WebDCS Warranty Coverage (validation) Inquiry Screen (Service > Warranty Coverage > Warranty Coverage Inquiry) for a list of any additional campaigns that may need to be performed on the vehicle before returning it to the customer.