2007 KIA CARNIVAL Workshop Manual

INSPECTION
1.Check the drive shaft spline for wear or damage.
2. Check that there is no water or foreign material in the BJ.
3. Check the spider assembly for roller rotation, wear or corrosion.
4. Check the groove inside the UTJ case for wear or corrosion.
5. Check the dynamic damper for damage or cracks.
DISASSEMBLY
a.Do not disassemble the BJ assembly.
b. The Driveshaft joint uses special grease. Do not subtitute with another type of grease.
c. The Boot band should be replaced with a new one.
1. Remove the TSJ boot band and pull the boot from TSJ outer race.
Be careful not to damage it.

2.Remove the circlip using a screwdriver.
3.Remove the driveshaft from TSJ outer race.
4.Remove the snap ring and disassemble the spider assembly from the shaft.
5. Clean the spider assembly.
6. Remove the BJ boot band and removal of the TSJ boot and the BJ boot.
If the boot is reused, wrap a tape around the driveshaft splines to protect the boot.

7.Remove both side of bands(B) of the dunamic damper(A).
8.Fix the drive shaft(A) with a vice(B) as illustrated.
9.Apply soapy water to the shaft to prevent being damaged between the shaftspline and the dynamic damper when
the dynamic damper is removed.
10. Separate dynamic damper(A) from the shaft(B) carefully.
DISASSEMBLY

a.Do not disassemble the BJ assembly.
b. Special grease must be applied to the drive shaft joint. Do not substitute with another type of grease.
c. The boot band should be replaced with a new one.
1. Remove the clip (B) from drive shaft splines (A) of the transaxle side.
2.Remove both boot bands from the transaxle side UTJ case.
3.Pull out the boot from the transaxle side joint(UTJ).
4. When separating the joint and boot (A), remove the grease from the UTJ case (B).
a.Be careful not to damage the boot.
b. According to ullustration below, put alignment marks across spider roller assembly (A), UTJ case (B), and
shaft splines (C) to aid in reassembly.

5.Using a plier or flat- tipped ( - ) screwdriver, remove the snap ring (A).
6.Remove the spider assembly (B) from drive shaft (A) by using the Special Tool(09495- 33000).
7.Clean the spider assembly.
8. Remove the boot (A), of the transaxle side joint(UTJ).
Wrap tape (B) around the driveshaft splines (C) to protect the boot (A).

9.Remove both side of bands (B, C) of the dynamic damper (A).
10. Fix the driveshaft (A) with a vice (B) as illustrated.
11.Apply soap powder on the shaft to prevent being damage between the shaft spline and the dynamic damper when
the dynamic damper is removal.
12. Separated dynamic damper (A) from the shaft (B) carefully.
13.Remove both bands on the side of wheel.

14.Pull out the joint(BJ) boot on the side of wheel into the transaxle direction.
Be careful not to damage the boot.
REASSEMBLY
1.Wrap tape around the drive shaft splines (UTJ side) to prevent damage to the boots.
2. Apply grease to the joint(BJ) boot on the side of wheel and install the boots.
3. Install the bands to both boots.
4.Using clamp, secure the boot bands.
Clearance (A) : 2.0 mm (0.079 in.) or less
5.To install the dynamic damper, keep the BJ shaft in a straight line and secure the dynamic damper with the
dynamic damper bands.
6. Install the UTJ boot bands and UTJ boot.
7. Using the alignment marks (D) made during disassembly as a guide, install the spider assembly (A) and snap ring
(B) on the driveshaft splines (C).

(B) on the driveshaft splines (C).
8.Add the specified grease to the joint(UTJ) boot as mush as wiped away at inspection.
9. Install the boots.
10. To control the air in the UTJ boot, keep the specified distance between the boot bands when they are tightened.
Standard value [A]
Items Standard (A) mm(in)
LH RH
2.9 Diesel M/T 505.4 (19.90)466.8 (18.38)
2.9 Diesel A/T 507.5 (19.98)466.9 (18.38)
3.8 Gasoline A/T 557.1 (21.93)570.7 (22.47)
11. Install both sides of the boot bands by using SST (09495- 39100).