Special Service Tools

Tool Name/Number	Illustration	Description
Sensor cap installer 09527 - AL500	Courtesy of KIA MOTORS AMERICA, INC.	Used for installing wheel speed sensor cap (Sensor cap: 86.6)

Replacement 

Rear Wheel Speed Sensor Cap 

1. Remove the rear wheel hub bearing assembly.

   (Refer to Driveshaft and axle - "REAR HUB ")

2. Fix the rear hub bearing assembly (A) on the vise.

   Courtesy of KIA MOTORS AMERICA, INC.

   NOTE:

   • When placing on the vise, use a cloth not to be damaged the hub bearing assembly.
   • Be careful not to use excessive force on the vise may damage the hub bearing assembly.
3. Check the direction of the sensor cap (A).

   Courtesy of KIA MOTORS AMERICA, INC.

   NOTE: Before removing the sensor cap, check the direction of the sensor cap connector.

   Courtesy of KIA MOTORS AMERICA, INC.

4. Remove the sensor cap by hammering on a gap between sensor cap and hub bearing assembly using a scraper (A).

   Courtesy of KIA MOTORS AMERICA, INC.

   NOTE:

   • In order to widen the gap little by little, hammering around the bearing cap 10 - 20 times.

   Courtesy of KIA MOTORS AMERICA, INC.

   • When removing the sensor cap, remove it in a straight direction not to damage the tone wheel or encoder.

   Courtesy of KIA MOTORS AMERICA, INC.

   • Be careful not to damage the hub bearing assembly when using the hammer.
5. Check for distortion of damage of the tone wheel or encoder (A).

   Courtesy of KIA MOTORS AMERICA, INC.

   NOTE:

   • Check if damaged the tone wheel or encoder after removing the sensor cap and replace the hub bearing if it was deformed.
   • If the tone wheel is deformed, it may trigger the MIL ON or other problems.

   Courtesy of KIA MOTORS AMERICA, INC.

6. Position the sensor cap to the same direction of sensor cap connector (A) as you checked before removing.

   Courtesy of KIA MOTORS AMERICA, INC.

   NOTE: Before installing the sensor cap, do not let any foreign material and contaminant into the hub bearing assembly.
7. Install the sensor cap (A) with the special service tool (09527 - AL500).

   Courtesy of KIA MOTORS AMERICA, INC.

   NOTE:

   • Be careful not to tilt to one side when installing the sensor cap as it may damage the tone wheel or encoder.
   • When sensor cap installation, hammering it until the gap disappeared between the sensor cap and hub bearing assembly.

   Courtesy of KIA MOTORS AMERICA, INC.

   • Special Service Tools guide.

   SST No.	SST Inner diameter	Sensor cap outer diameter
   09527 - 2W110	82.1	81.2, 81.4
   09527 - 1S010	58.9	58.4
   09527 - AL100	60	59.5
   09527 - AL200	65.9	65.3
   09527 - AL300	67.4	67.2
   09527 - AL400	73.2	72.6
   09527 - AL500	87.2	86.6

8. Install the rear wheel hub bearing assembly.

   (Refer to Driveshaft and axle - "REAR HUB ")