Hyundai Sonata: Front Suspension System / Sub Frame Repair procedures

Replacement
1.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the wheel cap (A).

   
Be careful not to damage to the wheel cap (A) when removing the it.
3.
Remove the front wheel and tire (A) from front hub.

Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

   
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
4.
Remove driveshaft nut (A) from the front hub under applying the brake.

Tightening torque :
274.6 ~ 294.2 N.m (28.0 ~ 30.0 kgf.m, 202.5 ~ 217.1 lb-ft)

   
The front hub coking nut should be replaced with new ones.
After installation coking nut (A), stake the coking nut using a chisel and hammer as shown in the illustration below.

5.
Remove the tie rod end ball joint (C) from the knuckle.
(1)
Remove the split pin (A).
(2)
Remove the castle nut (B).

Tightening torque :
34.3 ~ 44.0 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.5 lb-ft)

6.
Remove the lower arm (A).
(1)
Remove the split pin (B).
(2)
Loosen the mounting nut and bolt.

7.
Loosen the stabilizer link (A) and remove it from the shock absorber.

Tightening torque :
98.1 ~ 117.7 N.m (10.0 ~ 12.0 kgf.m, 72.3 ~ 86.8 lb-ft)

8.
Loosen the universal joint bolt (A) and then disconnect the universal joint assembly.

Tightening torque :
32.4 ~ 37.3 N.m (3.3 ~ 3.8 kgf.m, 23.9 ~ 27.5 lb-ft)

9.
Remove the engine room under cover (A).

Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

10.
Remove the roll rod bracket (A).

Tightening torque :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

11.
Disconnect the muffler rubber hanger (A).

12.
Loosen the bolts & nuts and then remove the sub frame (A).

Tightening torque :
Sub frame mounting bolt & nut
156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)
Sub frame stay mounting bolt
44.1 ~ 58.8 N.m(4.5 ~ 6.0kgf.m, 32.5~43.4 lb-ft)

13.
Loosen the mounting bolt and then remove the stabilizer bar (B) from the sub frame (A).

Tightening torque :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

14.
Remove the steering gear box. [R-MDPS Type]
(1)
Loosen the bolts and then remove the portector (A).

Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

(2)
Disconnect the all of the connector form the ECU.
(3)
Loosen the bolts and then remove the steering gear box (A).

Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 43.4 ~ 57.9 lb-ft)

15.
Loosen the bolt and then remove the steering gear box (A). [C-MDPS Type]

Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1~79.6 lb-ft)

16.
Remove the front lower arm (A) and then loosen the bolts & nuts.

Tightening torque
Front : 117.7 ~ 137.3 N.m (12.0 ~ 14.0 kgf.m, 86.8 ~ 101.3 lb-ft)
Rear : 156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)

17.
Installation is the reverse of removal.
18.
Check the wheel Alignment.
(Refer to Tires/Wheels - "Alignment")
Front Stabilizer Bar Repair procedures
Inspection 1. Raise the vehicle, and make sure it is securely supported. 2. Remove the wheel cap (A).     Be careful not to damage to the wheel cap (A) when removing the it. ...

Rear Suspension System
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