Kia Forte: Driveshaft Assembly / TJ Joint

Kia Forte 2019-2024 (BD) Service Manual / Driveshaft and axle / Driveshaft Assembly / TJ Joint

Components and components location

Components

[RH]

1. BJ assembly
2. Clip
3. BJ boot band
4. BJ boot

5. Dynamic damper band
6. Dynamic damper
7. Shaft
8. TJ boot band

9. TJ boot
10. Spider assembly
11. Circlip
12. TJ housing

13. Circlip

[LH]

1. BJ assembly
2. BJ circlip
3. BJ boot band
4. BJ boot

5. Shaft
6. TJ boot band
7. TJ boot
8. Spider assembly

9. Snap ring
10. TJ case
11. Circlip

Repair procedures

Disassembly

•	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 Front Driveshaft. (Refer to Driveshaft Assembly - “Front Driveshaft”)

2.	Remove the housing circlip (B) from the driveshaft spline (A).

3.	Remove both boot bands from the TJ housing.

Remove the TJ housing (A).

•	Make alignment marks (D) on spider roller assembly (A), TJ housing (B), and shaft spline (C) to aid reassembly.

5.	Remove the snap ring (A) from the shaft.

6.	Remove the spider assembly (B) from the driveshaft (A) using the puller.

7.	Clean the spider assembly.

Remove the TJ boot (A).

•	For reusing the boot (A), wrap tape (B) around the driveshaft splines (C) to protect the boot (A).

Inspection

1.	Check the spider assembly for roller rotation, wear or corrosion.

2.	Check the groove inside the joint case for wear or corrosion.

3.	Check the TJ boots for damage and deterioration.

Reassembly

1.	Wrap tape around the driveshaft spline (TJ) to prevent damaging the boot.

2.	Using the alignment marks (D) made during disassembly as a guide, install the spider assembly (A) and snap ring (B) on the driveshaft splines (C).

3.	Add specified grease to the joint boot as much as it was wiped away at inspection.

4.	Install both boot bands.

To control the air in the TJ boot, keep the specified distance between the boot bands when they are tightened.

Engine	Distance (L) mm (in.)
Engine	LH side	RH side
Gamma 1.6 MPI (MT)	537.9 (21.1772)	834.2 (32.8425)
Gamma 1.6 MPI (AT)	525.2 (20.6772)	814.5 (32.0669)
Nu 2.0 MPI (MT)	545.6 (21.4803)	826.2 (32.5276)
Nu 2.0 MPI (AT)	525.2 (20.6772)	814.5 (32.0669)
Gamma 1.6 T-GDI (DCT)	498.7 (19.6339)	517.6 (20.3780)
Gamma 1.6 T-GDI (MT)	530.5 (20.8858)	517.7 (20.3819)
New U 1.6 (DCT)	498.7 (19.6339)	872.9 (34.3661)
New U 1.6 (MT)	530.6 (20.8898)	841.2 (33.1181)

Using the SST (09495-3K000), secure the TJ boot bands.

Clearance (A): 2.0 mm (0.0787 in.) or less

7.	Install the front driveshaft. (Refer to Driveshaft Assembly - “Front Driveshaft”)

Front Driveshaft

Components and components location Components Location [Gamma 1.6 MPI, Nu 2.0 MPI, New U 1.6 TCI] 1. Drive shaft (LH) 2. Drive shaft (RH) ...

Dynamic Damper

Components and components location Components [RH] 1. BJ assembly 2. Clip 3. BJ boot band 4. BJ boot 5. Dynamic damper band 6. Dynami ...

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