SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2001
GROUP
Drive Shaft & Axle Drive Shaft
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DISASSEMBLY OF D.O.J. AND B.J.
DRIVE SHAFT (D.O.J.-B.J. TYPE)
Kit name
Illustration
Contents
Double offset joint kit
  • Clip (Retainer ring)
  • D.O.J. assy
  • Circlip
  • D.O.J. boot
  • Snap ring
  • D.O.J. boot band
  • Boot band
  • Grease
Double offset joint boot kit
  • Clip (Retainer ring)
  • Circlip
  • Snap ring
  • D.O.J. boot
  • D.O.J. boot band
  • Boot band
  • Grease
Birfield joint and shaft kit
  • Clip (Retainer ring)
  • Circlip
  • Snap ring
  • D.O.J. boot band
  • Boot bands
  • B.J. boot band
  • B.J. boot
  • B.J. assy
  • Dust cover
  • Grease
Birfield joint boot kit
  • Clip (Retainer ring)
  • Circlip
  • Snap ring
  • D.O.J. boot band
  • Boot bands
  • B.J. boot band
  • B.J. boot
  • Grease
Damper kit
  • Clip (Retainer ring)
  • Circlip
  • Snap ring
  • D.O.J. boot band
  • Boot band
  • Dynamic damper band
  • Dynamic damper
  • Grease

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DISASSEMBLY
  1. Do not disassemble the B.J. assembly. The drive shaft joint uses special grease. Do not substitute with another type of grease. The boot band should be replaced with a new one. Remove the D.O.J. boot bands and pull the D.O.J. boot from the D.O.J. outer race.

    NOTE
    Be careful not to damage the boot.
  1. Remove the circlip with a flat-blade screwdriver.

  1. Pull out the drive shaft from the D.O.J. outer race.

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

  1. Clean the inner race, cage and balls without disassembling.

  1. Remove the B.J. boot bands and pull out and D.O.J. boot and B.J. boot.

    NOTE
    If the boot is to be reused, wrap tape around the D.O.J. boot and B.J. boot.
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INSPECTION
  1. Inspect the drive shaft and drive shaft splines for wear, damage, bending or corrosion.

  1. Inspect the birfield joint for entry of water and/or foreign material.

  1. Check the double offset joint outer race, cage, balls and inner race for damage, corrosion or wear.

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ASSEMBLY
  1. Wrap tape around the drive shaft splines (D.O.J .side) to prevent damage to the boots.

  1. Apply grease to the drive shaft and install the boots.

    Recommended lubricant:
    B.J. Boot grease
    CENTOPLEX 278M/136K
    D.O.J. Boot grease
    AMBLYGON TA10/2A
  1. Apply the specified grease to the inner race and cage, install the cage so that it is offset on the race as shown.

    NOTE
    Use the grease included in the repair kit.
  1. Apply the specified grease to the cage and fit the balls into the cage.

  1. Install the chamfered side as shown, and then install the inner race onto the drive shaft, and install the snap ring.

  1. Apply 603 gr. (2.1 0.1 oz.) of specified grease to the outer race and install the outer race onto the drive shaft.

  1. Apply 40 3 gr. (1.4 0.1 oz.) of specified grease into the D.O.J. boot and install the boot.

    D.O.J. boot grease gr. (oz):
    Total
    100 6 (3.5 0.2)
    In the joint
    60 3 (2.1 0.1)
    In the boot
    40 3 (1.4 0.1)
  1. Tighten the D.O.J. boot bands.

  1. Add to the B.J. as much specified grease as was wiped away at the time of inspection.

  1. Install the boots.

  1. Tighten the B.J. boot bands.

  1. To control the air in the D.O.J. boot, keep the specified distance between the boot bands when they are tightened.