Hyundai introduced the Sonata in 1985 for the Korean market only; in 1988 the Sonata became available worldwide. The 2002 Hyundai Sonata was equipped with a 2.4-liter, in-line four-cylinder engine or an optional 2.7-liter V-6. The Sonata's CV half shaft or CV axle connects between the wheels and the transmission. Replacing the CV axle requires a degree of mechanical aptitude and should take about two hours.
Remove the initial torque from the lug nuts on the wheel you are working on, using a tire iron. Do not remove the lug nuts yet. Raise the front of the Sonata using a 2-ton jack, or a jack with greater capacity. Place jack stands beneath the front sub frame, on either side of the engine (do not place the jack stands beneath the control arms). Lower the car onto the jack stands. Remove the wheel lug nuts, then remove the wheel.
Remove the caliper mounting bracket bolts from behind the front rotor. These are the bolts that incorporate the caliper and bracket, not just the caliper. Use a 3/8-inch drive ratchet and socket to remove the bolts. Employ a ratchet handle extension if you need to apply more torque to remove the bolts. Remove the caliper mounting bracket with the caliper attached. Hang the caliper and bracket from the front strut coil spring, using a metal clothes hanger. Remove the disc brake rotor by hand and set it outside of your work area.
Remove the cotter pin from the end of the CV axle using pliers. Install a 32 mm spindle nut socket onto the axle nut. Attach a 1/2-inch drive breaker bar to the spindle nut socket, and remove the nut completely from the CV axle.
Install an axle puller tool body onto the lug studs of the Sonata. Install three lug nuts onto the lugs to hold the puller in place, by spinning them on by hand until snug. Install the axle puller threaded rod into the center of the puller body. Thread the rod tip into the end of the CV axle. Turn the threaded rod using a ratchet and socket until the rod begins to push the CV axle free from the hub bearing assembly. Do not push the CV half shaft back farther than 1/2 to 1 inch.
Remove the castle nut from the end of the outer tie rod stud. The stud extends through the steering knuckle from the tie rod. Use a 3/8-inch drive ratchet and socket to remove the castle nut. Use a pry bar to pry the tie rod end up and out of the steering knuckle assembly.
Remove the castle nut from the lower ball joint stud. The ball joint stud extends upward from the lower ball joint, through the bottom of the steering knuckle. Use a 3/8-inch drive ratchet and socket to remove the nut, then pry the ball joint stud free from the steering knuckle with a pry bar. When you are done, the steering knuckle should be completely free from both the outer tie rod and lower ball joint.
Turn the threaded rod on the axle puller with a ratchet and socket until the CV axle is completely free from the wheel bearing assembly. Place your free hand onto the CV half shaft behind the steering knuckle to feel when the shaft pops free from the bearing. Insert a pry bar into the upper portion of the steering knuckle, and pry the steering knuckle clear of the axle shaft. Use your free hand to hold the CV axle from dropping down suddenly. Remove the puller from the wheel hub.
Slide your body beneath the Sonata, in a position where you can physically access the inner CV axle end. This end is mounted into the transaxle. Insert a pry bar between the transaxle housing and the large bulb on the inner end of the half shaft. Push the handle of the pry bar toward the center of the Sonata to pry the CV axle free from the transaxle. Leave your free hand beneath the CV axle so that it does not fall near or onto you. Continue prying until you have freed the axle.
Install the inner end of the new CV axle into the transaxle, gently. Rotate the half shaft back and forth with your hand on the large bulb or inner CV joint. Push the shaft into the transaxle as you are wiggling it back and forth. This gentle movement and wiggling will align the splines of the axle with those on the inside of the transaxle. Continue pushing until the axle is seated, or you can push no further.
Thoroughly lubricate the outside end of the CV axle using a tub of bearing grease (there is no such thing as too much grease when combining the half shaft with the wheel bearing splines). Thoroughly grease the inside splines of the wheel bearing assembly. Pull the steering knuckle outward and the over the end of the CV shaft with one hand. Use your other hand to guide the axle into the rear of the wheel bearing assembly. Push the two parts together until some threads are showing on the outside of the wheel bearing.
Install the spindle nut onto the end of the axle, and spin the nut on slightly by hand. Do not tighten the axle nut at this point. Place your jack beneath the lower control arm. Lift the lower control arm while guiding the lower ball joint stud up and through the bottom of the steering knuckle. Install the castle nut onto the ball joint stud with your hand and spin it on by a few threads. Install the outer tie rod end onto the steering knuckle and place the castle nut on the tie rod.
Tighten the lower ball joint castle nut between 43 to 52 foot-pounds of torque, using a 1/2-inch drive torque wrench and socket. Tighten the outer tie rod end castle nut onto the steering knuckle using the 1/2-inch drive torque wrench and socket. The outer tie rod should be tightened between 17 and 25 foot-pounds of torque. At this point you can install the 32 mm spindle nut socket onto the torque wrench.
Install the disc brake rotor back onto the wheel hub. Spin a wheel nut onto one wheel stud to hold the rotor firmly onto the hub, using only your fingers. Unhook and inspect the caliper and bracket assembly. Make sure the brake pads are pushed as far outward as possible for proper fitting back over the rotor. Slide the caliper and bracket assembly back onto the rotor. Install and snug the caliper bracket mounting bolts using a ratchet and socket. Tighten the bolts to between 100 and 115 foot-pounds of torque, using a 1/2-inch torque wrench and socket.
Double-check your torque on the axle nut as well as the caliper bracket bolts, using a torque wrench and a socket. These bolts require the most torque. Remove the lug nut from the stud. Install the front wheel back onto the Sonata, and snug the wheel lug nuts using a tire iron. Raise the Sonata off of the jack stands with your jack, then remove the jack stands from beneath the car. Immediately tighten the wheel lug nuts to 80 foot-pounds of torque, using a 1/2-inch-drive torque wrench and socket.
