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Home >> Mitsubishi >> 2005 >> Lancer Evolution >> Repair and Diagnosis >> Drivelines & Axles >> Wheel Hubs >> Front Axle -- Evolution >> Drive Shaft Assembly >> EBJ Boot (Resin Boot) Replacement
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EBJ Boot (Resin Boot) Replacement

  1. Remove the boot bands (large and small).
    NOTE: The boot bands cannot be re-used.
  2. Remove the EBJ boot.
  3. Wrap a plastic tape around the shaft spline, and assemble the boot band and EBJ boot.
    Fig 1: Assembling Boot Band And EBJ Boot
    G02398624Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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
    G02398625Courtesy 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.
    NOTE: The adjusting bolt should not be turned more than once.
  6. Position the EBJ boot band (small) so that there is even clearance at either end (A and B).
    Fig 3: Turning Adjusting Bolt
    G02398626Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 4: Positioning EBJ Boot Band
    G02398627Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Secure the drive shaft 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 special tool MB991561 touches the stopper.
  7. Use special tool MB991561 to crimp the boot band (small).
    Fig 5: Crimping Boot Band (Small)
    G02398628Courtesy 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 (0.09 - 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) - 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 (C) Of Boot Band
    G02398629Courtesy 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 drive shaft 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: 100 +/- 10 g (3.5 +/- 0.3 ounces) 
  11. Align the center groove on the EBJ boot big end with the EBJ case groove.
    Fig 7: Aligning Center Groove On EBJ Boot Big End With EBJ Case Groove
    G02398630Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  12. Follow the same procedure as in step 5 to adjust the size of the opening (W) on special tool MB991561 so that it is at the standard value.
    • Standard value (W): 3.2 mm (0.13 inch) 
  13. Position the EBJ boot band (large) so that there is even clearance at either end (D and E).
    Fig 8: Positioning EBJ Boot Band (Large)
    G02398631Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. Use special tool MB991561 to crimp the EBJ boot band (large) in the same way as in step 7.
  15. 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 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.
    Fig 9: Checking Crimping Amount (F) Of Boot Band
    G02398632Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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