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Home >> Mitsubishi >> 2004 >> Lancer LS >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Wheel Hubs >> Front Axle Hub Assembly & Drive Shafts - Except Evolution & SPORTBACK >> Drive Shaft Assembly >> BJ/EBJ Boot (Resin Boot) Replacement
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BJ/EBJ Boot (Resin Boot) Replacement

  1. Remove the boot bands (large and small).
    NOTE: The boot bands cannot be reused.
  2. Remove the BJ/EBJ boot.
  3. Wrap a plastic tape around the shaft spline, and assemble the boot band and resin boot.
    Fig 1: Removing Boot Bands
    G00955130Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  4. Align the center groove on the BJ/EBJ boot small end with the shaft groove.
    Fig 2: Aligning Center Groove
    G00955131Courtesy 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.
    1. Standard value (W): 2.9 mm (0.11 inch) 
    2. < If it is larger than 2.9 mm (0.11 inch) > Tighten the adjusting bolt. 
    3. < 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 for each turn of the adjusting bolt.
    NOTE: The adjusting bolt should not be turned more than once.
    Fig 3: Measuring Standard Value
    G00955132Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. Position the BJ/EBJ boot and (small) so that there are even clearance at either end (B and C).
    Fig 4: Measuring Clearance
    G00955133Courtesy 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 the special tool MB991561 touches the stopper.
  7. Use the special MB991561 tool to crimp the boot band (small).
    Fig 5: Crimping Boot Band
    G00955134Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Check that the crimping amount (D) of the boot band is at the standard value.
    1. Standard value (D): 2.4 - 2.8 mm (0.10 - 0.11 mm) 
    2. < If the crimping amount is large than 2.8 mm (0.11 inch) > 
    3. Readjust the value of (W) in step   5  according to the following formula, and then repeat the operation in step   7 . 
    4. W = 5.5 mm (0.22 inch) - D 
    5. Example: If D = 2.9 mm (0.11 inch), then W = 2.6 mm (0.10 inch). 
    6. < If the crimping amount is smaller than 2.4 mm (0.10 inch) > 
    7. Remove the BJ/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 BJ/EBJ boot band. 
    8. W = 5.5 mm (0.22 inch) -D 
    9. 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
    G00955135Courtesy 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 the operations in 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.
    1. Specified grease: Repair kit grease 
    2. Amount to use (BJ): 95 +/- 10 g (3.4 +/- 0.3 oz.) 
    3. Amount to use (EBJ): 100 +/- 10 g (3.5 +/- 0.3 oz.) 
  11. Align the center groove on the BJ/EBJ boot big end with the shaft groove.
    Fig 7: Locating Grease Filling Point
    G00955136Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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.
    1. Standard value (W): 3.2 mm (0.13 inch) 
  13. Position the BJ/EBJ boot band (large) so that there are even clearance at either end (G and H).
    Fig 8: Measuring Clearance
    G00955137Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. Use the special tool MB991561 to crimp the B.J. boot band (large) in the same way as in step  7.
  15. Check that the crimping amount (I) of the boot band is at the standard value.
    Fig 9: Crimping B.J. Boot Band
    G00955138Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Standard value (I): 2.4 - 2.8 mm (0.10 - 0.11 inch) 
    2. < If the crimping amount is larger than 2.8 mm (0.11 inch) > 
    3. Readjust the value of (W) in step   12  according to the following formula, and then repeat the operation in step   14 . 
    4. W = 5.5 mm (0.22 inch) - I 
    5. Example: If I = 2.9 mm (0.11 inch), then W = 2.6 mm (0.10 inch). 
    6. < If the crimping amount is smaller than 2.4 mm (0.10 inch) > 
    7. Remove the BJ/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 BJ/EBJ boot band. 
    8. W = 5.5 mm (0.22 inch) -I 
    9. Example: If I = 2.3 mm (0.09 inch), then W = 3.2 mm (0.13 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 the operations in steps  13 to  15 using a new boot band.
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