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BJ Boot Replacement

  1. Remove the BJ boot bands (large or small).
    NOTE: The BJ boot bands cannot be re-used.
  2. Remove the BJ boot.
  3. Turn the adjusting bolt on the special tool numbered MB991561, so that the size of the opening "W" is at the standard value. See SERVICE SPECIFICATIONS  .
    NOTE: The value of "W" will change by approximately 0.03" (0.7 mm) for each turn of the adjusting bolt. The adjusting bolt should not be turned more than once.
  4. Place the BJ boot band (small) against the projection at the edge of the boot and then secure it so that there is a clearance. See Fig 1 .
    CAUTION: Secure the driveshaft in an upright position and clamp the part of the BJ boot band to be crimped securely in the jaws of the special tool numbered MB991561. Crimp the BJ boot band until the special tool numbered MB991561 touches the stopper. See SPECIAL TOOLS  .
  5. Use the special tool numbered MB991561, to crimp the BJ boot band (small). See SPECIAL TOOLS  .
  6. Check that the crimping amount "B" of the BJ boot band is at the standard value. See SERVICE SPECIFICATIONS  .
  7. Check that the BJ boot band in not sticking out past the place where it had been installed. If the BJ boot band is sticking out, remove it and then repeat the operations in steps  4 - 6 using a new boot band.
  8. Fill the inside of the BJ boot with repair kit grease. Grease quantity for 2.4L engine, 3.5-4.3 oz. (100-120 gr); for 3.0L engine, 3.8-4.6 oz. (110-130 gr).
  9. Install the BJ boot band (large) so that clearance "C" between it and the BJ housing is at the standard value. See SERVICE SPECIFICATIONS  .
  10. Follow the same procedure as in step  3 to adjust the size of the opening "W" on the special tool numbered MB991561 so that it is at the standard value. See SERVICE SPECIFICATIONS  .
  11. Place the BJ boot band (large) against the projection at the edge of the boot and then secure it, so that there is a clearance. See Fig 2 .
  12. Use the special tool numbered MB991561 to crimp the BJ boot band (large) in the same way as in step  5 . See SPECIAL TOOLS  .
  13. Check that the crimping amount "E" of the BJ boot band is at the standard value and that the crimping amount "F" of the BJ boot band is at the limited value. See SERVICE SPECIFICATIONS  .
  14. Check that the BJ boot is not sticking out past the place where it has been installed. If the BJ boot band is sticking out, remove it and then repeat operations in steps  11 - 13 using a new BJ boot band.
Fig 1: Installing BJ Boot Band (Small)
G00318334Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig 2: Installing BJ Boot Band (Large)
G00318335Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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