2001 Kia Rio

2001 DRIVE AXLES FWD Axle Shafts

2001 DRIVE AXLES

FWD Axle Shafts

DESCRIPTION

NOTE: For information on Spectra model, refer to Sephia unless otherwise directed.

Vehicles use inner and outer CV joints. Inner joint is a Tripod type joint. Outer joint is a Birfield type joint. CV
joints are enclosed by CV boots, which maintain lubrication and prevent contaminants from entering joints.

TROUBLE SHOOTING

NOTE: See DRIVE AXLE NOISE DIAGNOSIS article in GENERAL INFORMATION.

REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION

FRONT AXLE SHAFTS

Removal (Optima)

1. Raise and support vehicle. Remove wheel and tire assemblies. Drain transaxle.
2. Remove cotter pin then remove axle shaft nut from front hub. Disconnect lower control arm ball joint
from steering knuckle. Using plastic hammer, gently tap axle shaft out of front hub. Disconnect axle shaft
from front hub.
3. On 2.5L models, insert pry bar between transaxle case and left axle shaft. Pry axle shaft from transaxle.
Release drive belt auto tensioner, then remove drive belt. Remove alternator assembly. Using pry bar,
remove right axle shaft from center bearing assembly. Fig. 1 .
4. On 2.4L models, insert pry bar between transaxle case and drive shaft. Using hammer, lightly tap end of
pry bar to unseat inner joint housing from transaxle. Remove axle shaft. On all models, use puller (09432-
11000) to remove tone wheel from axle shaft hub.

NOTE: DO NOT disassemble outer CV joint. Replace outer joint housing as an

assembly. Service outer boot only after inner CV joint has been removed.

Removal (Rio)

1. Raise and support vehicle. Drain transaxle oil. Remove front wheels. Unstake axle shaft lock nut. Apply
brakes and loosen axle shaft lock nut.
2. Remove tension rod mounting nuts. Remove ball joint clamp bolt and nut from lower control arm.
Disconnect ball joint from lower control arm.
3. Remove stabilizer bar from control link. Using a pry bar, carefully separate axle shafts from transaxle. Do
not completely remove axle shafts at this time. Remove axle shaft lock nut and discard.

Helpmelearn Repair Manuals

4:59:17 PM
Monday, April 17, 2006 4:59:34 Page 1 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

4. Remove axle shafts from hub. Pull axle shaft from transaxle, discard retaining circlip. Install differential
side gear holder (0K130 111 002) into transaxle.

NOTE: DO NOT disassemble outer CV joint. Replace outer joint housing as an

assembly. Service outer boot only after inner CV joint has been removed.

NOTE: Before disassembling left axle shaft assembly, measure and record dynamic
damper position from axle shaft end for reassembly reference.

Removal (Sephia)

1. Raise and support vehicle. Remove front wheels. Unstake axle shaft lock nut. Apply brakes and remove
axle shaft lock nut. Remove cotter pin and tie rod end nut.
2. Using appropriate puller, separate tie rod end from steering knuckle. Disconnect stabilizer bar from lower
control arm. Disconnect lower control arm ball joint from steering knuckle.
3. On left axle shaft, carefully insert pry bar between inner joint housing and transaxle, ensuring no damage
to boot or oil seal occurs. Using hammer, lightly tap end of pry bar to unseat inner joint housing from
transaxle. On right axle shaft, using a brass drift and a hammer, drive axle shaft off of intermediate shaft.
4. On both axles, remove axle shaft assembly from hub. If axle shaft is frozen to hub, reinstall axle shaft
lock nut until flush with end of axle shaft and tap end of axle shaft with brass or plastic hammer.

NOTE: DO NOT disassemble outer CV joint. Replace outer joint housing as an

assembly. Service outer boot only after inner CV joint has been removed.

NOTE: Before disassembling left axle shaft assembly, measure and record dynamic
damper position from axle shaft end for reassembly reference.

Removal (Sportage)

1. Raise and support vehicle. Remove wheels. Remove bolts and remove free wheel hub body. Remove axle
shaft snap ring and spacer. Remove screws, set plate and lock nut. Remove bolts and remove brake
caliper assembly from steering knuckle. Support caliper assembly with wire.
2. Remove upper control arm link lock bolt, spring washer and nut. Remove cotter pin and nut from tie rod.
Using appropriate puller, remove tie rod from steering knuckle. Loosen drop link lower lock nut. Loosen
4 drop link upper lock nuts. Using a rubber hammer, spread drop link forks.
3. Index mark axle shaft position for installation reference. On right axle shaft, carefully insert pry bar
between inner joint housing and transaxle, ensuring no damage to boot or oil seal occurs. Pry axle shaft
from transaxle. On left axle shaft, remove axle shaft from differential assembly splined output shaft. On
both axles, remove axle shaft from hub.

NOTE: DO NOT disassemble outer CV joint. Replace outer joint housing as an

assembly. Service outer boot only after inner CV joint has been removed.

Disassembly (All Models)

Helpmelearn Repair Manuals
Monday, April 17, 2006 4:59:17 PM Page 2 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

1. Place axle shaft assembly in soft-jaw vise. Keep axle shaft assembly clean during disassembly and
reassembly. Remove CV joint boot bands, and slide boot away from CV joint housing. Index mark inner
joint housing, tripod assembly or cage assembly and axle shaft for reassembly reference.
2. Using a screwdriver, remove large circlip ring or stopper ring from inner race groove in inner joint
housing (if equipped). See Fig. 2 and Fig. 3 . Remove inner joint housing from tripod assembly or cage
assembly. Remove snap ring retaining tripod assembly or cage assembly to axle shaft. Using a hammer
and brass drift, drive tripod assembly or cage assembly from axle shaft.
3. Wrap axle shaft end with tape. Remove inner joint housing boot. Index mark and remove dynamic
damper (if equipped) as necessary. Remove outer joint housing boot bands and remove boot by sliding it
off inner joint housing end. On Sportage, remove dust cover from left axle shaft inner joint housing (if
necessary). On all models, clean and inspect all parts. Ensure axle shaft is not bent, twisted or damaged.
4. Check splines for wear. Inspect tripod bearings, cage assembly (inner ring, cage, and balls) for abnormal
wear, excessive looseness, seizure, rust or other damage. Replace as necessary.

Fig. 1: Exploded View Of Axle Shaft Assembly (Optima)

Courtesy of KIA MOTORS AMERICA, INC.

Helpmelearn Repair Manuals

Monday, April 17, 2006 4:59:18 PM Page 3 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

Fig. 2: Exploded View Of Axle Shaft Assembly (Rio & Sephia Left Side Axle Shaft Shown; Right Side Is
Similar)
Courtesy of KIA MOTORS AMERICA, INC.

Helpmelearn Repair Manuals

Monday, April 17, 2006 4:59:18 PM Page 4 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

Fig. 3: Exploded View Of Axle Shafts (Sportage)

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Inner and outer CV joint boots look similar but differ in diameter. Ensure correct
boot is installed at proper end when reassembling axle shaft. See Fig. 4 . See
FRONT AXLE SHAFT BOOT IDENTIFICATION table.

Reassembly

1. On Sportage, install dust cover onto inner joint housing. On all models, pack outer CV joint assembly
with grease. Wrap tape around axle shaft end and slide outer boot onto axle shaft (if removed). Install
dynamic damper and band (if removed). Slide inner CV joint boot onto axle shaft.
2.
NOTE: CV joint grease specifications for Sportage are not available from

Helpmelearn Repair Manuals

Monday, April 17, 2006 4:59:18 PM Page 5 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

manufacturer.

Align marks on tripod assembly or cage assembly and axle shaft. Using hammer and brass drift, install
tripod assembly or cage assembly onto axle shaft. Install snap ring. Apply grease into CV joint housing.
See CV JOINT GREASE SPECIFICATIONS table. Align marks on tripod assembly or cage assembly,
axle shaft and inner joint housing. Position joint housing onto tripod assembly or cage assembly and
install circlip or stopper ring (if equipped).
3. Remove trapped air by lifting boot off housing with a dull screwdriver. Ensure axle shaft is at specified
length. See Fig. 5 . See FRONT AXLE SHAFT LENGTH table. Ensure boot is properly seated. Using
NEW boot bands, position bands so when folded down, direction is opposite axle shaft direction of
rotation. Fold boot band back by pulling on end of band with pliers. Lock end of band by bending locking
clip.

Fig. 4: Identifying CV Joint Boot Dimensions

Courtesy of KIA MOTORS AMERICA, INC.

Fig. 5: Identifying Axle Shaft Dimensions

Courtesy of KIA MOTORS AMERICA, INC.
Helpmelearn Repair Manuals
Monday, April 17, 2006 4:59:18 PM Page 6 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

FRONT AXLE SHAFT BOOT IDENTIFICATION

Application (1) In. (mm)
Sephia
Differential Side Diameter 3.72 (94.5)
Wheel Side Diameter 3.46 (88.0)
Sportage
Differential Side Diameter 3.70 (94.0)
Wheel Side Diameter 3.86 (98.1)
(1) Front axle shaft boot identification information for Optima and Rio not available
from manufacturer.

CV JOINT GREASE SPECIFICATIONS

Application Ozs. (g)
Optima
2.4L
Wheel End 2.11 (60)
Transaxle End 3.52 (100)
2.5L
Wheel End 2.65 (75)
Transaxle End 3.52 (100)
Rio
Wheel End 3.52 (100)
Sephia
Transaxle End 4.94 (140)
Wheel End 4.58 (130)

FRONT AXLE SHAFT LENGTH

Application In. (mm)
Optima
2.4L
Left Axle Shaft 27.07 (687.6)
Right Axle Shaft 39.39 (1000.5)
2.5L
Left Axle Shaft 26.93 (683.9)
Right Axle Shaft 27.68 (703.4)
Rio
Left Axle Shaft
Automatic Transaxle 25.67 (652.0)
Manual Transaxle 25.67 (652.0)

Helpmelearn Repair Manuals

Monday, April 17, 2006 4:59:18 PM Page 7 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

Dynamic Damper (1) 19.00-19.26 (482.6-489.2)

Right Axle Shaft
Automatic Transaxle 14.93 (379.2)
Manual Transaxle 14.54 (369.2)
Sephia
Left Axle Shaft
Automatic Transaxle 25.16 (639.1)
Manual Transaxle 25.15 (638.8)
Right Axle Shaft
Automatic Transaxle 25.54 (648.7)
Manual Transaxle 24.93 (633.3)
Sportage
Left Axle Shaft 20.82 (528.7)
Right Axle Shaft 23.47 (596.2)
(1) Measured from wheel end.

Installation (Optima)

1. Install NEW circlip on inner joint housing of axle shafts. Inspect oil seals and seating surfaces to ensure
proper sealing. Replace seals as necessary. Coat drive shaft splines and differential case sliding surface
with gear oil.
2. On 2.5L models, install left axle shaft into transaxle as not to damage oil seal. Pull axle shaft outwards to
ensure it is seated properly. Carefully install right axle shaft into intermediate shaft.
3. On 2.4L models, install left axle shaft into transaxle so as not to damage oil seal. Pull axle shaft assembly
outward slightly to ensure it is properly seated. Repeat for right axle shaft.
4. On all models, pull outward on hub assembly and insert axle shaft into hub. Install axle shaft nut washer
with convex side down. Install axle shaft nut. Tighten to specification. To complete assembly, reverse
removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Apply
brakes and tighten axle shaft lock nut to specification. Add transaxle fluid. See appropriate
TRANSMISSION SERVICING article in TRANSMISSIONS.

Installation (Rio)

1. Remove differential side gear holder. Install NEW circlip onto inboard axle shaft end. Lubricate inboard
end of axle shafts with grease. Install inboard axle shaft ends into transaxle.
2. Lubricate, outboard end of axle shafts with grease. Insert outboard end of axle shafts into wheel hub.
Install axle shaft end nuts onto axle shafts, finger tighten nut.
3. Push up lower control arm, then reconnect ball joint. Install NEW axle shaft lock nuts onto axle shafts.
Tighten to specification. See TORQUE SPECIFICATIONS . Stake locknut.
4. To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE
SPECIFICATIONS . After installation, ensure wheels can be turned by hand. Refill transaxle with oil.
See appropriate TRANSMISSION SERVICING article under TRANSMISSIONS.
Helpmelearn Repair Manuals
Monday, April 17, 2006 4:59:18 PM Page 8 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

Installation (Sephia)

1. Install NEW circlip on inner joint housing of left axle shaft. Inspect oil seals and sealing surfaces to
ensure proper sealing. Replace seals as necessary.
2. Carefully install left axle shaft assembly into transaxle so as not to damage oil seal. Pull axle shaft
assembly outward to ensure axle shaft assembly is properly seated in transaxle. Install right axle shaft into
intermediate shaft. On both axle shafts, pull outward on hub assembly and insert axle shaft into hub.
Install NEW axle shaft lock nut.
3. Install lower control arm ball joint on steering knuckle. Install stabilizer bar and tie rod end. Tighten bolts
and nuts to specification. See TORQUE SPECIFICATIONS . Apply brakes and tighten axle shaft lock
nut to specification. Stake axle shaft lock nut. Add transaxle fluid or differential fluid as necessary.

Installation (Sportage)

1. Install NEW circlip onto inner joint housing of right axle shaft. Inspect oil seals and sealing surfaces to
ensure proper sealing. Replace seals as necessary. Align axle shaft position index marks made during
removal procedure. Carefully install right axle shaft assembly into transaxle so as not to damage oil seal.
Pull axle shaft assembly outward to ensure axle shaft assembly is properly seated in transaxle. Install left
axle shaft into differential assembly splined output shaft. On both axles, pull outward on hub assembly,
and insert axle shaft into hub.
2. Tighten drop link upper lock nuts and lower lock nut. Install upper control arm link lock bolt, spring
washer and nut. Install tie rod end to steering knuckle. Install nut and tighten to specification. Install
cotter pin. Install lock nut, set plate and screws. Install spacer. Install NEW axle shaft snap ring. Install
free wheel hub body and bolts. Install brake caliper assembly to steering knuckle. Install wheels. Tighten
bolts and nuts to specification. See TORQUE SPECIFICATIONS . Add transaxle fluid or differential
fluid as necessary.

BEARING HOUSING & OUTPUT SHAFT

NOTE: Intermediate shaft removal and installation procedures for Sephia are not
available from manufacturer.

Removal & Installation (Optima)

1. Remove right axle shaft. See appropriate procedure under FWD AXLE SHAFT . Remove center bearing
bracket bolts from cylinder block. Remove intermediate shaft from transaxle.
2. Using puller (09517-43001), remove center bearing bracket from inner shaft. Using adapter (09495-
33100 and 09216-21100), press out center bearing from bracket. See Fig. 6 . Discard oil seals and
bearing. Inspect Inner shaft for bending or rust. Inspect inner shaft splines for deformation or abnormal
wear. Replace if needed.
3. Apply multipurpose grease onto center bearing and inside run of center bearing bracket. Using adapter
(09495-33100), press center bearing into bracket.
4. Pack specified amount of grease into dust seals. See CENTER BEARING GREASE
SPECIFICATIONS . Using seal installer (09216-21600) and support (09216-21100), tap inner and outer
dust seals onto center bearing bracket assembly. Using support bracket (09432-33300), brace center
bearing bracket assembly. Press inner shaft into center bearing bracket assembly.
Helpmelearn Repair Manuals
Monday, April 17, 2006 4:59:18 PM Page 9 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

5. Install NEW clip onto input shaft groove. Install input shaft into transaxle assembly. Install center bearing
bracket bolts and tighten to specification. See TORQUE SPECIFICATIONS . To complete installation,
reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Fig. 6: Exploded View Of Center Bearing & Inner Shaft Assembly

Courtesy of KIA MOTORS AMERICA, INC.

CENTER BEARING GREASE SPECIFICATIONS

Application Ozs. (g)
Inner Dust Seal .25-.35 (7-10)
Outer Dust Seal .14-.21 (4-6)

Removal & Installation (Sportage)

1. Remove left axle shaft. See appropriate procedure under FWD AXLE SHAFT . Remove bearing housing
bolts. Remove output shaft with bearing housing from differential assembly. Remove "O" ring and clip.
Using a screwdriver, pry dust seal from bearing housing (if necessary). Using appropriate press, remove
bearing housing from output shaft. Using press and adapter, remove bearing from output shaft. See Fig.
7.
2. Inspect output shaft for bend, twist or damage. Check bearing for rough rotation or noise. Check bearing
housing for cracks or damage. Replace components as necessary.
3. Using appropriate seal installer and a hammer, install NEW dust seal into bearing housing. Using
appropriate press and adapter, install bearing onto output shaft. Using press, install output shaft with
bearing into bearing housing. Install NEW "O" ring into bearing housing. Install NEW clip into output
shaft groove. Install output shaft into differential assembly. Install bearing housing bolts and tighten to
specification.

Helpmelearn Repair Manuals

Monday, April 17, 2006 4:59:18 PM Page 10 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

Fig. 7: Exploded View Of Bearing Housing & Output Shaft Components (Sportage)
Courtesy of KIA MOTORS AMERICA, INC.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Axle Shaft Lock Nut
Optima 148-192 (201-260)
Rio 116-174 (157-235)
Sephia 154-205 (209-278)
Bearing Housing Bolt 34 (46)
Optima 29-36 (39-49)
Sportage 34 (46)
Brake Caliper Assembly-To-Steering Knuckle Bolts (Sportage) 72 (98)
Intermediate Shaft Support Bolt (Sephia) 31-46 (42-62)
Lower Control Arm Ball Joint-To-Steering Knuckle Nut
Optima 55-66 (75-90)
Rio 40-50 (54-68)
Helpmelearn Repair Manuals
Monday, April 17, 2006 4:59:18 PM Page 11 © 2004 Mitchell Repair Information Company, LLC.
 2001 Kia Rio
2001 DRIVE AXLES FWD Axle Shafts

Sephia 32-40 (43-54)

Sportage 109 (148)
Stabilizer Bar To Control Link Nut 32-45 (43-61)
Tension Rod Mounting Bracket Bolt (Rio) 87-108 (118-147)
Tie Rod End Nut
Sephia 21-32 (29-44)
Sportage 27 (36)
Upper Control Arm Lock Nut (Sportage) 36 (49)
Wheel Lug Nut
Optima 67-81 (90-110)
Sephia 65-87 (87-118)
Sportage 74 (100)

Helpmelearn Repair Manuals

Monday, April 17, 2006 4:59:18 PM Page 12 © 2004 Mitchell Repair Information Company, LLC.