03 Sorento front drive shaft install question - Page 2

gee6 · 01-15-2013, 05:02 AM

Unfortunately there had to be a reason for removing the front shaft. If you have no odd noises from the transmission with it reinstalled then I would have to guess it was damaged (UJ/CV) and high likelihood of poor maintenance.

Before you write off the TC, might be worth making sure the harness connector(s) to the transfer case are clean and good (if you/dealer didn't already).

kellmyster · 01-15-2013, 09:50 PM

I'll get under there again and check it out. I know when I dropped the TC crossbar support there was wires connected to it and they took a jolt when it dropped.
The dealer knew I wasn't going to buy a new transfer case, so I would think to get my money they would have fixed anything else I would have paid for. I'm checking rebuilders in the Seattle area. I guess these things are rebuildable.

gee6 · 01-16-2013, 06:05 AM

You can certainly source a replacement clutch pack, but not sure about other components. There is a least one supplier here who does refurbished transfer box for about £700+

I just saw a post on another forum that states Hi/Lo actuator is mounted on outside of transfer case and is "easily accesible", but I can't vouch for that.

cmar · 01-16-2013, 04:18 PM

Yes the Hi - Lo actuator is mounted on the rear end of the case. You can't miss it, an electric motor feeding into a right angle drive, the drive is the actual actuator, the motor supplies the power. A fault could be the motor, the drive, the wiring, or the ECU.

I just had a look under my car a 2003 with part time 4WD, and my front prop shaft just has ordinary U joints at both ends. I presume that the TOD units use a CV joint for durability because the shaft would be always turning, unlike a part time unit? Still the front diff doesn't move with the suspension like in a solid axle so I wonder why they bothered.

ejazz · 01-27-2013, 04:45 PM

Does anyone know where I can buy just the CV end of the propshaft pictured at the start of this thread? I have a 2003 with the auto engage 4x4 and just need to replace the one end. I have disassembled it and it is completely dry and the rubber is melted. Thanks.

gee6 · 01-28-2013, 01:47 AM

Pretty sure that you cannot buy the part on it's own. (There is a shaft for sale in UK - follow my sig and go to 'for sale' board - but you don't say where you are located, so that might not be any help.)

ejazz · 01-28-2013, 07:33 AM

I live in Central Wisconsin, United States. I see Dorman sells similar products but not for the Kia.