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Hyundai Santa Fe 2001-05

Overhaul 1

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Doj-Bj Type



The DOJ-BJ type joint is used on both the front and rear of the vehicle and the following overhaul procedure is used.



Click image to see an enlarged view

Fig. Exploded view of the DOJ-BJ type CV-joint assembly

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


NOTE
Do not disassemble the BJ assembly.

  1. Remove or disconnect the following:

    Axle halfshaft from the vehicle and place it in a vise
     
    DOJ boot clamps and push the boot back from the outer race
     
    Circlip with a flat bladed prytool
     
    Driveshaft from the DOJ outer race
     
    Snap-ring and take out the inner race, cage and balls as an assembly
     

  2.  
  3. Clean the outer race, cage and balls without disassembling them.

    BJ boot clamps
     
    DOJ and BJ boots
     

  4.  

To install:



Click image to see an enlarged view

Fig. Remove the boot clamps from the DOJ



Click image to see an enlarged view

Fig. Remove the circlip with a suitable tool



Click image to see an enlarged view

Fig. Remove snap-ring and take out the inner race, cage and balls as an assembly


NOTE
Use new circlips and boot clamps for assembly.

  1. Apply some of the grease supplied with the kit to the halfshaft..
  2.  
  3. Install the boots.
  4.  
  5. Apply the grease supplied with the kit to the inner race and cage.
  6.  
  7. Install the cage so that it is offset on the race.
  8.  
  9. Apply the grease supplied with the kit to the cage and install the balls
  10.  
  11. Install the chamfered side of the cage as shown in the accompanying illustration, then insert the inner race onto the shaft and install the snap-ring.
  12.  
  13. Apply the grease supplied with the kit to the BJ outer race (67-73 grams of grease in the joint and 62-68 grams of grease in the boot); and install the outer race onto the shaft.
  14.  
  15. Apply the grease supplied with the kit to the DOJ outer race (62-68 grams in the joint and 37-43 grams in the boot); and install the circlip.
  16.  
  17. Tighten the DOJ boot clamps.
  18.  
  19. Apply the grease supplied with the kit to the BJ.
  20.  
  21. Install the boots.
  22.  
  23. Tighten the BJ boot clamps
  24.  


NOTE
To control the volume of air in the DOJ boot, make sure the distance between the boot bands is as shown in the accompanying illustration.

  1. Install the axle halfshaft to the vehicle.
  2.  


    Click image to see an enlarged view

    Fig. Install the cage so that it is offset on the race



    Click image to see an enlarged view

    Fig. Install the chamfered side of the cage as shown



    Click image to see an enlarged view

    Fig. To control the volume of air in the DOJ boot, make sure the distance between the boot bands is as shown


The DOJ-BJ type joint is used on both the front and rear of the vehicle and the following overhaul procedure is used.

Click image to see an enlarged view

Fig. Exploded view of the DOJ-BJ type CV-joint assembly

  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    Do not disassemble the BJ assembly.

  2.  
  3. Remove or disconnect the following:

    Axle halfshaft from the vehicle and place it in a vise
     
    DOJ boot clamps and push the boot back from the outer race
     
    Circlip with a flat bladed prytool
     
    Driveshaft from the DOJ outer race
     
    Snap-ring and take out the inner race, cage and balls as an assembly
     

  4.  
  5. Clean the outer race, cage and balls without disassembling them.

    BJ boot clamps
     
    DOJ and BJ boots
     

  6.  

To install:

Click image to see an enlarged view

Fig. Remove the boot clamps from the DOJ



Click image to see an enlarged view

Fig. Remove the circlip with a suitable tool



Click image to see an enlarged view

Fig. Remove snap-ring and take out the inner race, cage and balls as an assembly


NOTE
Use new circlips and boot clamps for assembly.

  1. Apply some of the grease supplied with the kit to the halfshaft..
  2.  
  3. Install the boots.
  4.  
  5. Apply the grease supplied with the kit to the inner race and cage.
  6.  
  7. Install the cage so that it is offset on the race.
  8.  
  9. Apply the grease supplied with the kit to the cage and install the balls
  10.  
  11. Install the chamfered side of the cage as shown in the accompanying illustration, then insert the inner race onto the shaft and install the snap-ring.
  12.  
  13. Apply the grease supplied with the kit to the BJ outer race (67-73 grams of grease in the joint and 62-68 grams of grease in the boot); and install the outer race onto the shaft.
  14.  
  15. Apply the grease supplied with the kit to the DOJ outer race (62-68 grams in the joint and 37-43 grams in the boot); and install the circlip.
  16.  
  17. Tighten the DOJ boot clamps.
  18.  
  19. Apply the grease supplied with the kit to the BJ.
  20.  
  21. Install the boots.
  22.  
  23. Tighten the BJ boot clamps
    NOTE
    To control the volume of air in the DOJ boot, make sure the distance between the boot bands is as shown in the accompanying illustration.

  24.  
  25. Install the axle halfshaft to the vehicle.

    Click image to see an enlarged view

    Fig. Install the cage so that it is offset on the race



    Click image to see an enlarged view

    Fig. Install the chamfered side of the cage as shown



    Click image to see an enlarged view

    Fig. To control the volume of air in the DOJ boot, make sure the distance between the boot bands is as shown

  26.  

The DOJ-BJ type joint is used on both the front and rear of the vehicle and the following overhaul procedure is used.

Click image to see an enlarged view

Fig. Exploded view of the DOJ-BJ type CV-joint assembly

  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    Do not disassemble the BJ assembly.

  2.  
  3. Remove or disconnect the following:

    Axle halfshaft from the vehicle and place it in a vise
     
    DOJ boot clamps and push the boot back from the outer race
     
    Circlip with a flat bladed prytool
     
    Driveshaft from the DOJ outer race
     
    Snap-ring and take out the inner race, cage and balls as an assembly
     

  4.  
  5. Clean the outer race, cage and balls without disassembling them.

    BJ boot clamps
     
    DOJ and BJ boots
     

  6.  

To install:

Click image to see an enlarged view

Fig. Remove the boot clamps from the DOJ



Click image to see an enlarged view

Fig. Remove the circlip with a suitable tool



Click image to see an enlarged view

Fig. Remove snap-ring and take out the inner race, cage and balls as an assembly


NOTE
Use new circlips and boot clamps for assembly.

  1. Apply some of the grease supplied with the kit to the halfshaft..
  2.  
  3. Install the boots.
  4.  
  5. Apply the grease supplied with the kit to the inner race and cage.
  6.  
  7. Install the cage so that it is offset on the race.
  8.  
  9. Apply the grease supplied with the kit to the cage and install the balls
  10.  
  11. Install the chamfered side of the cage as shown in the accompanying illustration, then insert the inner race onto the shaft and install the snap-ring.
  12.  
  13. Apply the grease supplied with the kit to the BJ outer race (67-73 grams of grease in the joint and 62-68 grams of grease in the boot); and install the outer race onto the shaft.
  14.  
  15. Apply the grease supplied with the kit to the DOJ outer race (62-68 grams in the joint and 37-43 grams in the boot); and install the circlip.
  16.  
  17. Tighten the DOJ boot clamps.
  18.  
  19. Apply the grease supplied with the kit to the BJ.
  20.  
  21. Install the boots.
  22.  
  23. Tighten the BJ boot clamps
    NOTE
    To control the volume of air in the DOJ boot, make sure the distance between the boot bands is as shown in the accompanying illustration.

  24.  
  25. Install the axle halfshaft to the vehicle.

    Click image to see an enlarged view

    Fig. Install the cage so that it is offset on the race



    Click image to see an enlarged view

    Fig. Install the chamfered side of the cage as shown



    Click image to see an enlarged view

    Fig. To control the volume of air in the DOJ boot, make sure the distance between the boot bands is as shown

  26.  

 
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