2003 Kia Sorento LX

2003 DRIVE SHAFTS Front & Rear - Sorento

2003 DRIVE SHAFTS

Front & Rear - Sorento

GENERAL

NOTE: Drive shafts are referred to as propeller shafts in this article. Propeller (drive)
shafts are what transfer driveline power from transmissions and transfer cases
to the differentials.

SPECIFICATIONS

PROPELLER SHAFT

Fig. 1: Propeller Shaft Specifications

Courtesy of KIA MOTORS AMERICA, INC.

SPECIAL TOOLS

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 2003 Kia Sorento LX
2003 DRIVE SHAFTS Front & Rear - Sorento

Fig. 2: Special Tools (1 Of 4)

Courtesy of KIA MOTORS AMERICA, INC.

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 2003 Kia Sorento LX
2003 DRIVE SHAFTS Front & Rear - Sorento

Fig. 3: Special Tools (2 Of 4)

Courtesy of KIA MOTORS AMERICA, INC.

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 2003 Kia Sorento LX
2003 DRIVE SHAFTS Front & Rear - Sorento

Fig. 4: Special Tools (3 Of 4)

Courtesy of KIA MOTORS AMERICA, INC.

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 2003 Kia Sorento LX
2003 DRIVE SHAFTS Front & Rear - Sorento

Fig. 5: Special Tools (4 Of 4)

Courtesy of KIA MOTORS AMERICA, INC.

TROUBLESHOOTING

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2003 DRIVE SHAFTS Front & Rear - Sorento

Fig. 6: Driveline Trouble Shooting

Courtesy of KIA MOTORS AMERICA, INC.

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2003 DRIVE SHAFTS Front & Rear - Sorento

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Fig. 7: Differential Trouble Shooting

Courtesy of KIA MOTORS AMERICA, INC.

PROPELLER SHAFT ASSEMBLY

PROPELLER SHAFT

COMPONENTS

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2003 DRIVE SHAFTS Front & Rear - Sorento

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Fig. 8: Propeller Shaft Components

Courtesy of KIA MOTORS AMERICA, INC.

ON-VEHICLE SERVICE

If noise or vibration is present in the vehicle driveline, the propeller shaft may be out of round due to damage.
This inspection will help determine if the propeller shaft and its attaching driveline components are "true" or
turning with an absolute minimum amount of lateral movement.

SPLINE BACKLASH

Check for spline backlash by shaking propeller shaft back and forth.

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 2003 Kia Sorento LX
2003 DRIVE SHAFTS Front & Rear - Sorento

LOOSE UNIVERSALS

Check for loose universal yoke bolts and nuts. Tighten if necessary.

PROPELLER SHAFT DEFLECTION

1. Place transmission in neutral.

2. Raise and support vehicle.
3. Install a dial indicator to the vehicle undercarriage and place the indicator plunger on the propeller shaft.
4. Measure both shafts in three separate locations: At the center and 3 in (76.2 mm) from each yoke weld.
Slowly turn one of the wheels to turn the propeller shaft and record the highest indicator reading in all
three locations.

Deflection limit:

0.3 mm (0.012 in) or less.

REMOVAL

NOTE: z When removing the propeller shaft, be careful not to damage the dust
cover or spline.

1. Raise and support vehicle.

2. Place index marks (reference marks) on the propeller shaft and their matching transfer case and
differential input shafts.

Fig. 9: Make Index Marks On Propeller Shaft & On Matching Transfer Case & Differential Input
Shafts
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 2003 Kia Sorento LX
2003 DRIVE SHAFTS Front & Rear - Sorento

Courtesy of KIA MOTORS AMERICA, INC.

3. Remove four bolts holding universal flange to transfer case (4WD). Remove bolts holding center bearing
bracket (2WD).

Fig. 10: Identifying Bolts Holding Center Bearing Bracket (2WD)

Courtesy of KIA MOTORS AMERICA, INC.

4. Remove four bolts holding universal flange to differential.

5. Remove propeller shaft.

INSPECTION

1. Check the sleeve yoke, center yoke and flange yoke for wear, damage or cracks.
2. Check the propeller shaft yokes for wear, damage or cracks.
3. Check the propeller shaft for bends, twisting or damage.

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 2003 Kia Sorento LX
2003 DRIVE SHAFTS Front & Rear - Sorento

4. Check the universal joints for smooth operation in all directions.

Fig. 11: Inspecting Universal Joints For Damage

Courtesy of KIA MOTORS AMERICA, INC.

5. Check the center bearing for smooth movement (2WD).

6. Check the center bearing mounting rubber for damage or deterioration (4WD).
7. Measure the propeller shaft runout with a dial indicator.

Fig. 12: Propeller Shaft Runout Specifications Table

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 2003 Kia Sorento LX
2003 DRIVE SHAFTS Front & Rear - Sorento

Courtesy of KIA MOTORS AMERICA, INC.

Fig. 13: Measuring Propeller Shaft Runout

Courtesy of KIA MOTORS AMERICA, INC.

INSTALLATION

1. Connect propeller shaft flange to companion flange on front differential (4WD).

a. Align index marks on the flange and connect the flanges with four bolts and nuts.
b. Tighten the bolts and nuts.

Tightening torque:

26-30 N.m (2.6-3.0 kg. m, 19-21 lb. ft) - Full time 4WD

50-60 N.m (5.0-6.0 kg. m, 36-43 lb. ft) - Part time 4WD

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 2003 Kia Sorento LX
2003 DRIVE SHAFTS Front & Rear - Sorento

2. Connect front propeller shaft flange to companion flange on transfer case (4WD).
a. Align index marks on the flange and connect the flanges with four bolts and nuts.
b. Tighten the bolts.

Tightening torque:

50-60 N.m (5.0-6.0 kg. m, 36-43 lb. ft)

3. Connect rear propeller shaft flange to companion flange on transfer case. (4WD)
a. Align index marks on the flange and connect the flanges with four bolts and nuts.
b. Tighten the bolts.

Tightening torque:

50-60 N.m (5.0-6.0 kg. m, 36-43 lb. ft)

4. Connect the propeller shaft spline to transmission (2WD).

a. Align index mark on the spline and then install the propeller shaft.
b. Tighten the bolts holding the center bearing bracket.

Tightening torque:

37-54 N.m (3.7-5.4 kg. m, 27-39 lb. ft)

CAUTION: z Be careful not to damage the dust cover of propeller shaft

when installing the propeller shaft (2WD).

5. Connect propeller shaft flange to companion flange on rear differential.

a. Align index marks on the flange and connect the flange with four bolts and nuts.
b. Tighten the bolts and nuts.

Tightening torque:

50-60 N.m (5.0-6.0 kg. m, 36-43 lb. ft)

6. After installing the propeller shaft, fill grease into nipple until it comes out from sleeve yoke plug hole.

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