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Home >> Mitsubishi >> 2005 >> Lancer Evolution >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 30 (Front Axle -- Except Evolution) >> Drive Shaft Assembly >> BJ/EBJ Boot (Resin Boot) Replacement
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BJ/EBJ Boot (Resin Boot) Replacement

WARNING: This page is about a different variant/trim than selected.
  1. Remove the boot bands (large and small).
    NOTE: The boot bands cannot be re-used.
  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 BJ/EBJ Boot
    G02413973Courtesy 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 On BJ/EBJ Boot Small End With Shaft Groove
    G02413974Courtesy 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 for each turn of the adjusting bolt.
    NOTE: The adjusting bolt should not be turned more than once.
    Fig 3: Turning Adjusting Bolt To Adjust Size Of Opening
    G02413975Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. Position the BJ/EBJ boot band (small) so that there are even clearance at either end (B and C).
    Fig 4: Positioning BJ/EBJ Boot Band (Small)
    G02413976Courtesy 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 (Small)
    G02413977Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Check that the crimping amount (D) of the boot band is at the standard value.
    • Standard value (D): 2.4 - 2.8 mm (0.10 - 0.11 mm) 
    • < 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 (0.10 inch) > 
    • 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. 
    • 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 (D) Of Boot Band
    G02413978Courtesy 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 7 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 (BJ): 95 +/- 10 g (3.4 +/- 0.3 oz) 
      • 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: Aligning Center Groove On BJ/EBJ Boot Big End With Shaft Groove
    G02413979Courtesy 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.
    • 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: Positioning BJ/EBJ Boot Band (Large)
    G02413980Courtesy 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.
    • Standard value (I): 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 = 5.5 mm (0.22 inch) - I 
    • Example: If I = 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 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. 
    • W = 5.5 mm (0.22 inch) - I 
    • Example: If I = 2.3 mm (0.09 inch), then W = 3.2 mm (0.13 inch). 
    Fig 9: Crimping B.J. Boot Band (Large)
    G02413981Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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 14to  15 using a new boot band.
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