Hyundai Tucson: Rear Driveshaft Assembly / Rear Driveshaft Repair procedures

Removal
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the rear wheel and tire (A) from rear hub.

Tightening torque:
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

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

Tightening torque:
274.6 ~ 294.2 N.m (28.0 ~ 30.0 kgf.m, 202.5 ~ 217.0 lb-ft)

4.
Remove the parking brake cable.
(Refer to Brake System - "Parking Brake Cable")
5.
Remove the rear upper arm (A) after loosen the bolt (B).

Tightening torque
2WD :
137.2 ~ 156.9N.m (14.0 ~ 16.0kgf.m, 101.2 ~115.7 lb-ft)
4WD :
98.0 ~ 117.6 N.m (10.0 ~ 12.0 kgf.m, 72.3 ~ 86.7 lb-ft)

[2WD]

[4WD]

6.
Remove the brake hose (A) and wheel speed sensor (B).

Tightening torque:
Brake bose braket bolt : 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
Wheel speed senosr braket bolt : 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
Wheel speed senosr mounting bolt : 6.8 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 7.9 lb-ft)

7.
Remove the rear assist arm (B) after loosen the bolt (A).

Tightening torque:
2WD : 4.5 ~ 5.5 kgf.m
4WD : 14.0 ~ 16.0 kgf.m

[2WD]

[4WD]

8.
Loosen the nuts & bolts and then remove the trailing arm (A) with the rear axle.

Tightening torque :
Trailing arm :
44.1 ~ 53.9N.m (4.5 ~ 5.5kgf.m, 32.5 ~ 39.8lb-ft)
Parking brake cable bracket :
6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0lb-ft)

9.
Separate the end (A) of rear driveshaft on rear axle assembly.
   
To prevent damage to the drive shaft.
Check for damage after the completion of work.

10.
Insert a pry bar (A) between the differential case (B) and joint case (C), and separate the driveshaft (D) from the differential case.
   
Use a pry bar being careful not to damage the transaxle and joint.
Do not insert the pry bar too deep, as this may cause damage to the oil seal.
Do not pull the driveshaft by excessive force it may cause components inside the joint kit to dislodge resulting in a torn boot or a damaged bearing.
Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
Support the driveshaft properly.
Replace the retainer ring whenever the driveshaft is removed from the transaxle case.

11.
Install in the reverse order of removal.
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 driveshaft for cracks and wears.
5.
Check the TJ outer race, inner race, cage and balls for rust or damage.
6.
Check for water, foreign matter, or rust in the BJ boot.
   
When the BJ assembly (A) is to be reused, do not wipe away the grease.
Check that there are no foreign substances in the grease. If necessary, clean the BJ assembly (A) and replace grease.

Disassembly
   
Do not disassemble the 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 TJ boot bands and pull the TJ boot from the TJ outer race.
(1)
Using a pliers or flat-tipped (-) screwdriver, remove the LH boot band and LH TJ boot band from the driveshaft.
(2)
Remove RH boot band and RH TJ boot band in the same way of LH removal procedure.
   
Be careful not to damage the boot.
2.
Pull out the driveshaft from the TJ outer race.
3.
Remove the snap ring (A) and take out the inner race (B), cage (C) and balls (D) as an assembly.

4.
Clean the inner race, cage and balls without disassembling.
5.
Remove the BJ boot bands and pull out the TJ boot and BJ boot.
   
If the boot (A) is to be reused, wrap tape (B) around the driveshaft splines (C) to protect the boot (A).

Reassembly
1.
Wrap tape around the driveshaft splines (TJ side ) to prevent damage to the boots.
2.
Apply grease to the driveshaft and install the boots.
3.
Apply the specified grease to the inner race (A) and cage (B). Install the cage (B) so that it is offset on the race as shown.
   
Use the grease included in the repair kit.

4.
Apply the specified grease to the cage and fit the balls into the cage.
5.
Position the chamfered side (A) as shown in the illustration. Install the inner race on the driveshaft (B), and then the snap ring.

6.
Apply the specified grease to the outer race and install the BJ outer race onto the driveshaft.
7.
Apply the specified grease into the TJ boot and install the boot with a clip.
8.
Tighten the TJ boot bands.
9.
Add the specified grease to the BJ as much as wiped away at inspection.
10.
Install the boots.
11.
Tighten the BJ boot bands.
12.
To control the air in the TJ boot, keep the specified distance between the boot bands when they are tightened.
Distance (mm)
LH
RH
ALL
702.9mm
(27.7 in.)
683.7mm
(26.9 in.)

Rear Driveshaft Components and Components Location
Components 1. Tone wheel2. BJ joint3. BJ boot4. BJ boot big part band5. BJ boot small part band6. Shaft7. TJ boot small part band8. TJ boot big part band9. TJ boot10. Snap ring11. Circlip12. TJ a ...

Propeller Shaft Assembly
...

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