2003 Hyundai Santa Fe - R Drive-Axle Replacement

Joined
Jul 7, 2014
Messages
7,709
Location
Winnipeg MB CA
This vehicle (2003 Hyundai Santa Fe 2.7 FWD 201,000 km) belongs to a friend, a widow in her 80s without the resources to replace it.

Note the multi-region body deterioration - it's sunbaked like a Colorado car, and rusting out like a local car.

In May I found a bad ball joint and split boots on both front CV joints. I had too many things going on, and did not offer to do the work.

The R one was much worse, and I figured the CV joint on that side would fail within a few months.

She had the ball joint replaced by an indy mechanic, but declined to have the driveshafts done due to the expense.

Well, here we are ... a few days ago the front R started making a bad noise - clicking, rattling, thumping, banging, etc. I volunteered.

My wife dropped me off at the owner's place last night, and I drove home gingerly right across town. Made it!

I fired up the heater in the garage and started taking things apart.

Observations:
1. The castellated axle nut was missing its cotter pin.
2. The castellated nut for the outer tie-rod end was also missing its cotter pin.
3. The outer tie-rod end has a zerk - it must be aftermarket.
4. The tie-rod end popped out fairly easily with the little press
5. One of the strut-to-knuckle bolts came out easily. The other one was a beast. Lots of time hammering away with the impact wrench, but it eventually came out.
6. So now, the fun part ... as feared, the axle spline is seized in the knuckle. I have the press on it, and will leave it for a few hours. Will try to tighten it periodically. I'm hoping ...

20251208_125212_HDR.webp
20251208_125156.webp
 
Time for the 50/50 acetone-ATF mix.
I have some I mixed a while ago. The problem is getting it into something that sits horizontally.

What I did back in 2017 on our Mazda5 was to install an old plastic mayonnaise jar onto the knuckle, over the end of the shaft. I drilled a hole in the top and filled it with Kroil.

Left it a day, and went back at it. Success, eventually. I don't know how much the penetrating oil helped.

I can't take any credit - I saw it on a Subaru forum.

full-64751-21170-img_5567.webp
 
What about a little heat and the old crayon or candle trick? A couple careful taps with a hammer on the puller bolt may help too.

BTW - have a good look at the sub-frame for rust and rot. My niece had issues with hers.
 
What about a little heat and the old crayon or candle trick? A couple careful taps with a hammer on the puller bolt may help too.

BTW - have a good look at the sub-frame for rust and rot. My niece had issues with hers.
First thing that crossed my mind when I read the post ! sub frame rot......
 
Thanks, it seems like the right thing to do. I really hope I can get the spline out of the hub/knuckle. It should go OK after that.
I have never had a problem with this when I've had to replace a CV joint or axle.
I guess I've just been lucky.
Agree that once you get it apart things should go easily.
The bravery is in getting into an old banger that may have many other issues.
 
I have never had a problem with this when I've had to replace a CV joint or axle.
I guess I've just been lucky.
Agree that once you get it apart things should go easily.
The bravery is in getting into an old banger that may have many other issues.
It's unpredictable - I did the other (passenger) side of the '09 Mazda5 several years later, and the spline came out no problem.

Just a few months ago I had to remove the knuckle on a 2009 Kia Sedona to replace a wheel bearing, and again, no problem at all.

And yet, I'm not alone - YouTube has a number of videos of folks dealing with splined drive axles rusted into knuckle/hub assemblies.

Anyway, it's sitting there in the garage with the press cranked down - perhaps it'll pop free overnight.
 
It's unpredictable - I did the other (passenger) side of the '09 Mazda5 several years later, and the spline came out no problem.

Just a few months ago I had to remove the knuckle on a 2009 Kia Sedona to replace a wheel bearing, and again, no problem at all.

And yet, I'm not alone - YouTube has a number of videos of folks dealing with splined drive axles rusted into knuckle/hub assemblies.

Anyway, it's sitting there in the garage with the press cranked down - perhaps it'll pop free overnight.
You have my best wishes on that.
There's always the hard way as well.
 
20251208_203646.webp
20251208_203634.webp

"This is not the end. It is not even the beginning of the end. But it is, perhaps, the end of the beginning."

- Winston Churchill, November, 1942, after the tide had turned in the Allies' favour in North Africa.

I imagine more fun lies ahead, removing the drive axle. Per at least one YouTube video, the axle splits in the middle, using another splined joint. 😜

I can hardly wait ...
 
I have some I mixed a while ago. The problem is getting it into something that sits horizontally.

What I did back in 2017 on our Mazda5 was to install an old plastic mayonnaise jar onto the knuckle, over the end of the shaft. I drilled a hole in the top and filled it with Kroil.

Left it a day, and went back at it. Success, eventually. I don't know how much the penetrating oil helped.

I can't take any credit - I saw it on a Subaru forum.

View attachment 313926
I can accept the credit going partially to your wise Kroil use.

I never forgot the near miracle it became in our maintenance shops and across the plant site for pesky issues. At times , some things that took a torch to get apart would break down after just an over night soaking in Kroil just like you pulled off(y).

My last Kroil use was on a set of rear brake drums on a pick up truck that was used in a lot of damp and wet locations that pretty much had seized them on. One single night of Kroil soaking in the shop followed by a good rap with a mall and they both popped right off as if they were just installed. Yeah.... EXPENSIVE but worth it. Kroil should pay me and many I know who sing it's praises! ;)
 
It would seem OP doesn't own an air hammer? If not, you need one. Especially if you deal with situations like this.
 
It would seem OP doesn't own an air hammer? If not, you need one. Especially if you deal with situations like this.
I do - but didn't even think of using it. I wish I had - it might have saved me some time.

Per @crashz's suggestion, I did beat on the end of the puller/press tool, which I think helped quite a lot. Used my trusty 4# persuader.
 
Back
Top Bottom