Kia Forte: Rear Suspension System - Couple Torsion Beam Axle / Rear Torsion Beam Axle

Kia Forte 2019-2020 (BD) Service Manual / Suspension System / Rear Suspension System - Couple Torsion Beam Axle / Rear Torsion Beam Axle

Components and components location
Components

1. Torsion beam axle
2. Torsion beam axle cover

Repair procedures
Removal and Installation
1.

Remove the rear wheel and tire (A).

Tightening torque:

107.9 - 127.5 N·m (11.0 - 13.0 kgf·m, 79.6 - 94.0 lb·ft)

  

Be careful not to damage to the hub bolts when removing the rear wheel and tire.

2.

Disconnect the rear wheel speed sensor bracket (A).

Tightening torque:

8.8 - 13.7 N·m (0.9 - 1.4 kgf·m, 6.5 - 10.1 lb·ft)

3.

Disconnect the parking brake cable bracket (A).

Tightening torque:

8.8 - 13.7 N·m (0.9 - 1.4 kgf·m, 6.5 - 10.1 lb·ft)

4.

Remove the rear hub bearing assembly.

(Refer to Driveshaft and axle - "Rear Hub - Carrier")

5.

Remove the torsion beam axle under cover (A).

6.

Support the jack to torsion beam axle (A).

7.

Loosen the lower mounting bolt and then detach the rear shock absorber (A).

Tightening torque:

98.0 - 117.6 N·m (10.0 - 12.0 kgf·m, 72.3 - 86.7 lb·ft)

8.

Remove the coil spring (A).

9.

Remove the torsion beam axle mounting bolts (A).

Tightening torque:

156.9 - 176.5 N·m (16.0 - 18.0 kgf·m, 115.7 - 130.2 lb·ft)

[RH]

[LH]

10.

Remove the torsion beam axle (A).

11.

Install in the reverse order of removal.

12.

Check the wheel alignment.

(Refer to Rear Suspension System - "Rear Alignment")

Replacement

CTBA (Coupled Torsion Beam Axle) bush

Steel type
  

Get rid of foreign substance on the thread of main bolt and nut.

Apply grease (lubricant) on main bolt and bearing every each operation time.

Operate after cooling every each time because main bolt and nut have chance to be worn out caused by over heating from continuous operation.

1.

Using a SST (09551-AL100), replace the CTBA (Coupled Torsion Beam Axle) bush.

1. Beam clamp A
2. Beam clamp bolt
3. Beam clamp adapter
4. Beam clamp B
5. Beam clamp C
6. Installer adapter A
7. Installer adapter B
8. Beam clamp support
9. Bush guide A
10. Bush guide B
11. Remover adapter A
12. Remover adapter B
13. Installer adapter C
14. Safety cap
15. Bearing
16. Bearing washer
17. Nut
18. Main bolt
19. Main nut
20. Safety wire
21. Bush guide bolt

2.

Measure outer diameter of the torsion beam axle.

Outer diameter of the torsion beam axle has 78 mm (3.0709 in) and 84 mm (3.3071 in) two types.

3.

Install the beam clamp adapter (A) on beam clamp A (B).

  

Torsion beam axle outer diameter 78mm (3.0709 in) : apply beam clamp adapter

Torsion beam axle outer diameter 84mm (3.3071 in) : do not apply beam clamp adapter

4.

Pre-install the beam clamp A (A) and the beam clamp C (B) with bolt.

  

Torsion beam axle outer diameter 78mm (3.0709 in) : apply the beam clamp C

Torsion beam axle outer diameter 84mm (3.3071 in) : apply the beam clamp B

5.

Mark on the torsion beam axle which matches with bush groove.

6.

Assemble the bolt after installing the beam clamp (A) on the beam pipe accurately.

7.

Assemble the main bolt (A) and the main nut (B), then insert it into the beam clamp support (C).

8.

Align the main nut hole (A) and bolt (B) exactly, then assemble them.

  

Tool can be damaged if the hole positions are not align exactly.

9.

Assemble the beam support (B) and the beam clamp guide by aligning them after inserting the main bolt (A) into bush hole.

10.

Install it on the main bolt by the order of remover adapter A (A), bearing (B) and washer (C).

  

Torsion beam axle outer diameter 78mm (3.0709 in) : apply the remover adapter A

Torsion beam axle outer diameter 84mm (3.3071 in) : apply the remover adapter B

11.

Pre-install the 2 nuts (A).

12.

Install by double nut method with spanner and torque wrench.

Tightening torque : 49.0 N·m (5.0 kgf·m, 36.2 lb·ft)

13.

Install SST properly by rotating the main bolt (A) counterclockwise.

14.

Install the safety cap (A).

15.

Connect the safety wire (A) by winding once around torsion beam axle.

  

There is a chance to be harmed caused of bounced off tool by nut loosening if the safety wire is not connected while operating.

16.

Remove the bush by rotating the main bolt (A) counterclockwise using by air impact wrench.

In this procedure check if the nut is loosening or not by eyesight through the hole of cap (B). And if the nut is loosening then re-tighten by regulated torque.

17.

Disassemble the safety wire (A) after fully removal of the bush.

18.

Remove the bush and SST from the torsion beam axle.

19.

Remove the bush (A) by disassembling of the SST.

20.

Remove the beam clamp (A) from the torsion beam axle.

21.

Install the bush after matching the mark on the new bush and the mark on the torsion beam axle.

22.

Assemble the main bolt (A) and the main nut (B), then insert them into the Installer adapter B (C).

  

Torsion beam axle outer diameter 78mm (3.0709 in) : apply the installer adapter B

Torsion beam axle outer diameter 84mm (3.3071 in) : apply the installer adapter A

23.

Align the main nut hole (A) and volt (B) exactly, then assemble them.

  

Tool can be damaged if the hole positions are not align exactly.

24.

Install the installer adapter (B) by inserting the main bolt (A) into the bush hole.

  

Place groove of the installer adapter at welding part of the torsion beam, then install it.

25.

Install it on the main bolt by the order of installer adapter C (A), bearing (B) and washer (C).

26.

Pre-install two nut (A).

27.

Install by double nut method with spanner and torque wrench.

Tightening torque : 49.0 N·m (5.0 kgf·m, 36.2 lb·ft)

28.

Install SST properly by rotating the main bolt (A) counterclockwise.

29.

Install the safety cap (A).

30.

Connect the safety wire (A) by winding once around torsion beam axle.

  

There is a chance to be harmed caused of bounced off tool by nut loosening if the safety wire is not connected while operating.

31.

Install until it has 5 mm (0.1969 in) gap between the bush and torsion beam axle by rotating the main bolt (A) counterclockwise with air impact wrench.

In this procedure check if the nut is loosening or not by eyesight through the hole of cap (B). And if the nut is loosening then re-tighten by regulated torque.

32.

Rotate the main bolt counterclockwise until the bush and the end of the torsion beam are matched by using a hand wrench.

  

Proper installation of the Bush is completed if there is no gap by checking with eyesight.

33.

Release pressured tools by rotating the main bolt (A) clockwise after fully installation of the bush.

34.

Disassemble the safety wire (A).

35.

Remove the SST from the torsion beam axle.

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