EBJ Boot Replacement

Required Special Tool: 

MB991561: Boot Band Crimping Tool

1. Remove the boot bands (large and small).
   NOTE: The boot bands cannot be re-used.
   Fig 1: Removing EBJ Boot Band

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Remove the EBJ boot.
3. Wrap a plastic tape around the shaft spline, and assemble the boot band and EBJ boot.
4. Align the center groove on the EBJ boot small end with the shaft groove.
   Fig 2: Aligning Center Groove On EBJ Boot Small End With Shaft Groove

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. 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.
   • 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.
6. Position the EBJ boot band (small) so that there is even clearance at either end (A and B).
   Fig 4: Identifying EBJ Boot Band Position (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 the special tool MB991561.
   • Crimp the boot band until special tool MB991561 touches the stopper.
7. Use special tool MB991561 to crimp the boot band (small).
   Fig 5: Crimping Boot Band

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. Check that the crimping amount (C) of the boot band is at the standard value.

   Standard value (C): 2.4 - 2.8 mm (0.10 - 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) - C 

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

   If the crimping amount is smaller than 2.4 mm (0.10 inch) 

   Remove the EBJ 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 EBJ boot band. 

   W = 5.5 mm (0.22 inch) - C 

   Example: If C = 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.
9. Check that the boot band is not sticking out past the place where it has been installed. If the boot band is sticking 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.
10. Fill the inside of the boot with the specified amount of the specified grease.

    Specified grease: Repair kit grease 

    Amount to use: 105 ± 10 g (3.7 ± 0.3 ounces) 

11. Align the center groove on the EBJ boot big end with the EBJ case groove.
12. Follow the same procedure as in step  5 to adjust the size of the opening (W) on the special tool so that it is at the standard value.

    Standard value (W): 3.2 mm (0.13 inch) 

    Fig 7: Identifying Center Groove On EBJ Boot Big

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
13. Position the EBJ boot band (large) so that there is even clearance at either end (D and E).
14. Use special tool MB991561 to crimp the EBJ boot band (large) in the same way as in step  7.
    Fig 8: Identifying EBJ Boot Band Position (Large)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
15. Check that the crimping amount (F) of the boot band is at the standard value.
    Fig 9: Identifying Crimping Amount Of Boot Band

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    Standard value (F): 2.4 - 2.8 mm (0.10 - 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 (0.10 inch) 

    Remove the EBJ 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 EBJ 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) 

16. Check that the boot band is not sticking out past the place where it has been installed. If the boot band is sticking out, remove it and then repeat steps  13 to  15, using a new boot band.