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#615775 - 06/17/05 05:37 PM READ FIRST IF YOUR 4WD DOES NOT WORK *****
Axe Man Offline

Kia Moderator Emeritus
Registered: 03/02/02
Posts: 4497
Loc: Highland, NY
Condition: The green 4WD light is on when in 4H or 4L but there is no power to the front wheels. How come?

Problem: The front hubs are either damaged or not functioning.


Reason 1: If you have a 1995 - 1997 Sportage they came from the factory with Warn low speed automechanical hubs. These hubs wear out over time or may have been damaged due to a high speed shift from 2H to 4H. They were designed to be engaged either from a stop or under 15 MPH. Higher speed engagement will damage them. They also do not hold up well in rough off road conditions and will start disengaging even in 4WD.

Reason 2: If you have a 1998 - 2002 Sportage they came from the factory with "shift on fly" high speed vacuum hubs. With these hubs you could shift from 2H to 4H up to speeds of 50 MPH. It was a great idea but they don't work. The vacuum seals on the back of the hub area is VERY prone to leaking. When there is a vacuum leak the hubs will not engage. Kia attempted to fix this with a "double seal" design on later Sportages. That fix has been inadequate too. Once the vacuum seal is compromised dirt and moisture can enter the hub area and damage the wheel bearings.

Solution: There are 2 versions of hubs available from Warn industries that can be installed on any year Sportage. You can find Warn at http://www.warn.com


Manual Locking Hubs: Warn part number 60247. These are manually locking hubs that you must engage by hand at each wheel whenever you want to use 4WD. Once you shift back to 2H you can unlock them. You CAN leave them locked in while in 2H but fuel mileage will suffer because you are now turning the front axles and front differential. If the hubs are locked in you can "shift on the fly" at high speed. The advantage of these hubs is that they are absolutely bullet proof and reliable. They can take rough off road abuse and you'll always be assured that the 4 wheel drive will work.

Automechanical Locking Hubs: Warn part number 61918. These are a much improved version of the automechancial hubs originally installed on 1995 - 1997 Sportages. They can be engaged at much higher speeds and don't require vacuum for engagement. Disadvantages is that they are more expensive than manual hubs and they cannot take much abuse. They are for light 4 wheel drive duty only.


Installation: Either hub type can be installed on any year Sportage. Warn includes detailed installation instructions including pictures. Simply follow the directions for the ORIGINAL hub type you are removing. No special tools are required however snap ring pliers are helpful. On 1998 - 2002 Sportages there are some additional steps to take after installing the hubs. Remove the vacuum line in each fenderwell. Cut it off at both ends at the strut bracket. Plug the vacuum port on the backside of the hub with a screw and automotive epoxy. The vacuum line that projects into the fender area can be left unplugged. In the engine compartment locate the vacuum solenoid up behind the air filter. Unplug the electrical connector that comes up from underneath and tape it off. The plastic hubcaps on 1998 - 2002 Sportages will not fit over either hub. And you need access to the manual hubs to engage or disengage them. A solution is to slice off the top of the hub cap and then install it. Or leave it off. 1995 - 1997 Sportages have a different style hubcap with a plastic center piece that removes to allow access to the manual hubs.
_________________________
1998 Sportage - Gone.
2004 Honda Civic Coupe.
2007 Suzuki Grand Vitara - She got it.
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#615776 - 11/02/05 03:10 AM Re: READ FIRST IF YOUR 4WD DOES NOT WORK [Re: Axe Man]
Anonymous
Unregistered

Hello,
I am new to the forums, great article on the vacuum hubs, very helpful. I do have a question though. I am trying to figure out how the vacuum system inherent in the KIA 4WD's work. Right from the switch in the cab, through to the hubs actually engaging. Does anyone have any idea of where to find a diagram etc? Canada Customs isn't agreeing with my contentions that the Vacuum Hub Locks, are part of a vacuum control assembly (that being the swtich, lines, seals, valves etc). Can anyone help with how the whole system works and the parts involved in the vacuum system?
Thanks,
Disgruntled with the Government.
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#615777 - 11/02/05 02:36 PM Re: READ FIRST IF YOUR 4WD DOES NOT WORK
Axe Man Offline

Kia Moderator Emeritus
Registered: 03/02/02
Posts: 4497
Loc: Highland, NY
Quote:
Hello,
I am new to the forums, great article on the vacuum hubs, very helpful. I do have a question though. I am trying to figure out how the vacuum system inherent in the KIA 4WD's work. Right from the switch in the cab, through to the hubs actually engaging. Does anyone have any idea of where to find a diagram etc? Canada Customs isn't agreeing with my contentions that the Vacuum Hub Locks, are part of a vacuum control assembly (that being the swtich, lines, seals, valves etc). Can anyone help with how the whole system works and the parts involved in the vacuum system?
Thanks,
Disgruntled with the Government.


Just behind the air filter assembly is the vacuum soleniod. When you shift to 4H or 4L an electrical signal is sent to the soleniod. It picks and manifold vacuum is applied to the hubs. The hubs then engage which applies power to the front wheels. If you want the diagram I have it. Send me an e-mail at mjats@juno.com
_________________________
1998 Sportage - Gone.
2004 Honda Civic Coupe.
2007 Suzuki Grand Vitara - She got it.
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#615778 - 06/10/06 10:38 PM Re: READ FIRST IF YOUR 4WD DOES NOT WORK [Re: Axe Man]
mike1 Offline
Need a Spot
Registered: 06/10/06
Posts: 2
Loc: pembrokeshire england
thanks axe man
i bought my 1999 kia sportage 2 months ago and took it out on a 4x4 day within the first 10 mins i was stuck deep in mud and getting towed out i didnt have a clue why until i found this web site. front hubs didnt lock in because the vac hoses split. i replaced them with fuel injection hoses ( alot thicker ) and all 4 wheels going just the job.
but i will be getting some warn hubs when i can get them imported into this country. one thing i have got to ask can i put bigger tyres on the 15" rimes that came with it, without effecting the suspension cant afford a lift kit just yet, i want the warn hubs first. over here the kia is a "soft off roader" but i want to prove them wrong.
thanks again axe man you helped more than you will know

mike
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#615779 - 06/11/06 01:04 AM Re: READ FIRST IF YOUR 4WD DOES NOT WORK [Re: mike1]
Axe Man Offline

Kia Moderator Emeritus
Registered: 03/02/02
Posts: 4497
Loc: Highland, NY
Good deal Mike...glad I could help. <img src="/forums/images/graemlins/kewl.gif" alt="" /> If you can't find Warn hubs in the UK then try AVM. See this link...

http://www.avm.com.br/avm.htm

They also make front hubs for the Sportage and I know they can be purchased in Europe even though they are located in Brazil.
_________________________
1998 Sportage - Gone.
2004 Honda Civic Coupe.
2007 Suzuki Grand Vitara - She got it.
Top
#615780 - 07/21/06 03:57 AM Re: READ FIRST IF YOUR 4WD DOES NOT WORK [Re: mike1]
Anonymous
Unregistered

Quote:
thanks axe man
i bought my 1999 kia sportage 2 months ago and took it out on a 4x4 day within the first 10 mins i was stuck deep in mud and getting towed out i didnt have a clue why until i found this web site. front hubs didnt lock in because the vac hoses split. i replaced them with fuel injection hoses ( alot thicker )....

my problem exactly - great info in this thread. would anyone know where i might be able to get details on how to replace these hoses?

thanks in advance!
Top
#615781 - 07/24/06 11:10 PM Re: READ FIRST IF YOUR 4WD DOES NOT WORK
Axe Man Offline

Kia Moderator Emeritus
Registered: 03/02/02
Posts: 4497
Loc: Highland, NY
Quote:
Quote:
thanks axe man
i bought my 1999 kia sportage 2 months ago and took it out on a 4x4 day within the first 10 mins i was stuck deep in mud and getting towed out i didnt have a clue why until i found this web site. front hubs didnt lock in because the vac hoses split. i replaced them with fuel injection hoses ( alot thicker )....

my problem exactly - great info in this thread. would anyone know where i might be able to get details on how to replace these hoses?

thanks in advance!



You are better off replacing the hubs as described. Even if you fix the vacuum lines the hubs are still prone to leak at the back of the hub.
_________________________
1998 Sportage - Gone.
2004 Honda Civic Coupe.
2007 Suzuki Grand Vitara - She got it.
Top
#615782 - 08/12/06 01:28 AM Re: READ FIRST IF YOUR 4WD DOES NOT WORK [Re: Axe Man]
Anonymous
Unregistered

it's supposed that if I put wheels straight and don't touch the wheel, the car will go straight by itself, but it doesn't, it always goes to the right, and it just alsways wants to go to the right - very hard to drive. Also when I drive on low speeds I can feel that it's shaking.
What can it be ? <img src="/forums/images/graemlins/rolleyes.gif" alt="" />
Top
#615783 - 08/12/06 06:28 PM Re: READ FIRST IF YOUR 4WD DOES NOT WORK
Cen_Tex_KIA Offline
Mudrunner
Registered: 02/10/05
Posts: 402
Loc: Waco, Texas
1st step is to have you're front end aligned. That will tell you what needs to be replaced if any and correct you're directional problem. 2nd, have all youre tires rebalanced,thats teh most common cause of vibration at speed.
_________________________
2000 KIA Sportage 4x4, Sadly Smushed! Now a 2001 Cheep Jerokee. 3" Rough Country Lift, 255/70/16 General AT2's
http://www.cardomain.com/ride/2292811
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#615784 - 08/12/06 11:08 PM Re: READ FIRST IF YOUR 4WD DOES NOT WORK [Re: Cen_Tex_KIA]
turtleskia Offline
Mudrunner
Registered: 06/04/06
Posts: 331
Loc: on the streets
vibration at low speeds? could be a loose wheel bearing. just a thought.
_________________________
95 sportage, gone and severly missed.
94 camaro 5-speed v6 with a few addons.
girlfriends 93 s-10 4.3 soon to be lifted and made into a pre-runner
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