Hyundai_Tucson_2005

Overhaul

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Tripot Joint-Birfield Joint Type





Click image to see an enlarged view

Fig. Exploded view of halfshaft components-TJ-BJ Type

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft and place into a vise.
  4.  
  5. Remove the circlip from the splines of the transaxle side Tripot Joint (TJ) case.
  6.  
  7. Remove both boot clamps from the transaxle side TJ case.
  8.  
  9. Pull off the outer TJ boot.
  10.  
  11. Matchmark the trunion assembly to the TJ case and halfshaft spline.

    Click image to see an enlarged view

    Fig. Mark the joint assembly as shown-TJ-BJ type

  12.  
  13. Remove the circlip from the splines of the trunion assembly side.
  14.  
  15. Using Special Tool 09495-33000, remove the trunion assembly from the halfshaft.

    Click image to see an enlarged view

    Fig. Using special tool 09495-33000 to remove the trunion assembly

  16.  
  17. Remove the inner TJ boot.
  18.  
  19. Remove the dynamic damper clamps.
  20.  
  21. Separate the dynamic damper from the halfshaft, being careful not to damage the shaft splines.
  22.  
  23. Remove the Birfield Joint (BJ) boot clamp.
  24.  
  25. Remove the BJ being careful not to damage the boot.
  26.  

To install:


NOTE
Wrap tape around the axle shaft splines to prevent damage to the boots during assembly.


NOTE
Use new circlips and boot clamps for assembly.

  1. Apply grease to the halfshaft and install the BJ, boots and clamps.
  2.  
  3. Install the dynamic damper, keep the halfshaft straight and tighten the dynamic band.
  4.  
  5. Install the inner TJ boot and band.
  6.  
  7. Install the trunion assembly and circlip, aligning the matchmarks with each other.
  8.  
  9. Add the specified grease to the TJ, replaced all that was wiped away.
  10.  
  11. Install the outer TJ boot and clamp.
  12.  
  13. Install the halfshaft.
  14.  



Click image to see an enlarged view

Fig. Exploded view of halfshaft components-TJ-BJ Type

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft and place into a vise.
  4.  
  5. Remove the circlip from the splines of the transaxle side Tripot Joint (TJ) case.
  6.  
  7. Remove both boot clamps from the transaxle side TJ case.
  8.  
  9. Pull off the outer TJ boot.
  10.  
  11. Matchmark the trunion assembly to the TJ case and halfshaft spline.

    Click image to see an enlarged view

    Fig. Mark the joint assembly as shown-TJ-BJ type

  12.  
  13. Remove the circlip from the splines of the trunion assembly side.
  14.  
  15. Using Special Tool 09495-33000, remove the trunion assembly from the halfshaft.

    Click image to see an enlarged view

    Fig. Using special tool 09495-33000 to remove the trunion assembly

  16.  
  17. Remove the inner TJ boot.
  18.  
  19. Remove the dynamic damper clamps.
  20.  
  21. Separate the dynamic damper from the halfshaft, being careful not to damage the shaft splines.
  22.  
  23. Remove the Birfield Joint (BJ) boot clamp.
  24.  
  25. Remove the BJ being careful not to damage the boot.
  26.  

To install:


NOTE
Wrap tape around the axle shaft splines to prevent damage to the boots during assembly.


NOTE
Use new circlips and boot clamps for assembly.

  1. Apply grease to the halfshaft and install the BJ, boots and clamps.
  2.  
  3. Install the dynamic damper, keep the halfshaft straight and tighten the dynamic band.
  4.  
  5. Install the inner TJ boot and band.
  6.  
  7. Install the trunion assembly and circlip, aligning the matchmarks with each other.
  8.  
  9. Add the specified grease to the TJ, replaced all that was wiped away.
  10.  
  11. Install the outer TJ boot and clamp.
  12.  
  13. Install the halfshaft.
  14.  

Double Offset Joint (DOJ) Type





Click image to see an enlarged view

Fig. Exploded view of halfshaft components-DOJ-BJ Type

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft and place into a vise.
  4.  
  5. Remove the Double Offset Joint (DOJ) boot bands.
  6.  
  7. Pull the DOJ boot from the outer race.
  8.  
  9. Remove the circlip from the DOJ and pull the halfshaft from the outer race.
  10.  
  11. Remove the snap ring and take out the inner race assembly.
  12.  
  13. Remove the Birfield Joint (BJ) boot bands.
  14.  
  15. Pull out the DOJ boot and BJ boot.
    NOTE
    If the boots are to be reused, wrap tape around the halfshaft splines.

  16.  

To install:


NOTE
Use new circlips and boot clamps for assembly.

  1. Apply some boot grease to the halfshaft and install the boots.
  2.  
  3. Apply the specified kit grease to the inner race and cage.
  4.  
  5. Install the cage so that it is offset on the inner race as shown.

    Click image to see an enlarged view

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

  6.  
  7. Apply the specified grease to the cage and fit the balls into the cage.
  8.  
  9. Position the chamfered side as shown. Install the inner race on the halfshaft and install the snap ring.

    Click image to see an enlarged view

    Fig. Install the chamfered side of the cage as shown

  10.  
  11. Apply the specified grease to the BJ outer race and install the outer race onto the halfshaft.
  12.  
  13. Apply the specified grease into the DOJ boot and install the boot onto the halfshaft.
  14.  
  15. Tighten the DOJ boot bands.
  16.  
  17. Add the specified grease to the BJ to replace what was wiped away.
  18.  
  19. Install the boots and tighten the BJ boot bands.
  20.  
  21. Install the halfshaft.
  22.  



Click image to see an enlarged view

Fig. Exploded view of halfshaft components-DOJ-BJ Type

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft and place into a vise.
  4.  
  5. Remove the Double Offset Joint (DOJ) boot bands.
  6.  
  7. Pull the DOJ boot from the outer race.
  8.  
  9. Remove the circlip from the DOJ and pull the halfshaft from the outer race.
  10.  
  11. Remove the snap ring and take out the inner race assembly.
  12.  
  13. Remove the Birfield Joint (BJ) boot bands.
  14.  
  15. Pull out the DOJ boot and BJ boot.
    NOTE
    If the boots are to be reused, wrap tape around the halfshaft splines.

  16.  

To install:


NOTE
Use new circlips and boot clamps for assembly.

  1. Apply some boot grease to the halfshaft and install the boots.
  2.  
  3. Apply the specified kit grease to the inner race and cage.
  4.  
  5. Install the cage so that it is offset on the inner race as shown.

    Click image to see an enlarged view

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

  6.  
  7. Apply the specified grease to the cage and fit the balls into the cage.
  8.  
  9. Position the chamfered side as shown. Install the inner race on the halfshaft and install the snap ring.

    Click image to see an enlarged view

    Fig. Install the chamfered side of the cage as shown

  10.  
  11. Apply the specified grease to the BJ outer race and install the outer race onto the halfshaft.
  12.  
  13. Apply the specified grease into the DOJ boot and install the boot onto the halfshaft.
  14.  
  15. Tighten the DOJ boot bands.
  16.  
  17. Add the specified grease to the BJ to replace what was wiped away.
  18.  
  19. Install the boots and tighten the BJ boot bands.
  20.  
  21. Install the halfshaft.
  22.  

 
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