BJ Boot Replacement

Required Special Tool:

MB991561: Boot Band Crimping Tool

Remove the boot bands (large and small).
NOTE: The boot bands cannot be re-used.
Remove the BJ boot.
Wrap a plastic tape around the shaft spline, and assemble the boot band and BJ boot.

Fig 1: Removing Boot Band
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Align the center groove on the BJ boot small end with the shaft groove.

Fig 2: Aligning Center Groove On BJ/EBJ Boot Small End With Shaft Groove
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Turn the adjusting bolt on special tool MB991561 so that the size of the opening (W) is at the standard value.
Standard value (W): 2.9 mm (0.11 inch)

< If it is larger than 2.9 mm (0.11 inch)> Tighten the adjusting bolt.

< If it is smaller than 2.9 mm (0.11 inch)> Loosen the adjusting bolt.

NOTE: The value of W will change by approximately 0.7 mm (0.03 inch) for each turn of the adjusting bolt.

NOTE: The adjusting bolt should not be turned more than once.

Fig 3: Identifying Adjusting Bolt On Special Tool MB991561
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Position the BJ boot band (small) so that there is even clearance at either end (A and B).

Fig 4: Identifying BJ Boot Band (Small)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Secure the driveshaft in an upright position and clamp part of the boot band to be crimped securely in the jaws of special tool MB991561.
- Crimp the boot band until the special tool touches the stopper.
Use special tool MB991561 to crimp the boot band (small).

Fig 5: Crimping Boot Band (Small) Using Special Tool MB991561
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Check that the crimping amount (C) of the boot band is at the standard value.
Standard value (D): 2.4 - 2.8 mm (0.09 - 0.11 inch)

< If the crimping amount is larger than 2.8 mm (0.11 inch)>

Readjust the value of (W) in step 5 according to the following formula, and then repeat the operation in step 7.

W = 5.5 mm (0.22 inch) - D

Example: If D = 2.9 mm (0.11 inch), then W = 2.6 mm (0.10 inch).

< If the crimping amount is smaller than 2.4 mm (0.09 inch)>

Remove the BJ boot band, readjust the value of (W) in step 5 according to the following formula, and then repeat the operations in steps 6 and 7 using a new BJ boot band.

W = 5.5 mm (0.22 inch) - D

Example: If D = 2.3 mm (0.09 inch), then W = 3.2 mm (0.13 inch).

Fig 6: Checking Crimping Amount Of Boot Band
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Check that the boot band does not stick out past the place where it has been installed. If the boot band sticks out, remove it and then repeat steps 6 to 8, using a new boot band.
CAUTION: The driveshaft joint uses special grease. Do not mix old and new or different types of grease.
Fill the inside of the boot with the specified amount of the specified grease.
Specified grease: Repair kit grease

Amount to use: 120 ± 10 g (4.2 ± 0.3 ounces) <2.4L>

Amount to use: 165 ± 10 g (5.8 ± 0.3 ounces) <3.8L>
Align the center groove on the BJ boot big end with the BJ case groove.

Fig 7: Aligning Center Groove On BJ/EBJ Boot Big End With BJ/EBJ Case Groove
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Follow the same procedure as in step 5 to adjust the size of the opening (W) on special tool so that it is at the standard value.
Standard value (W): 2.9 mm (0.11 inch)
Position the BJ boot band (large) so that there is even clearance at either end (D and E).

Fig 8: Identifying BJ Boot Band (Large)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool to crimp the BJ boot band (large) in the same way as in step 7.
Check that the crimping amount (F) of the boot band is at the standard value.
Standard value (F): 2.4 - 2.8 mm (0.09 - 0.11 inch)

< If the crimping amount is larger than 2.8 mm (0.11 inch)>

Readjust the value of (W) in step 12 > according to the following formula, and then repeat the operation in step 14>.

W = 5.8 mm (0.23 inch) - F

Example: If F = 2.9 mm (0.11 inch), then W = 2.9 mm (0.11 inch).

< If the crimping amount is smaller than 2.4 mm (0.09 inch)>

Remove the BJ boot band, readjust the value of (W) in step 12 > according to the following formula, and then repeat the operations in steps 13 > and 14 > using a new BJ boot band.

W = 5.8 mm (0.23 inch) - F

Example: If F = 2.3 mm (0.09 inch), then W = 3.5 mm (0.14 inch).

Fig 9: Checking Crimping Amount (F) Of Boot Band
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Check that the boot band does not stick out past the place where it has been installed. If the boot band sticks out, remove it and then repeat steps 13> to 15>, using a new boot band.