Page 1897 of 3870
After applying the specified grease to the TJ case, insert the drive shaft and apply
grease again.
Specified grease: Repair kit grease
Amount to use: 125 +/- 10 g (4.4 +/- 0.3 ounces)
Fig. 43: Locating Grease Area On TJ Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION: The drive shaft joint use special grease. Do not mix
old and new or different types of grease.
NOTE: The grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor
Page 1898 of 3870
>>E<< TJ BOOT BAND (SMALL) < RH> /TJ BOOT BAND (LARGE) INSTALLATION < RH>Set the TJ boot bands at the specified distance in order to adjust the amount of air
inside the TJ boot, and then tighten the TJ boot band (small), TJ boot band (large)
securely.
Standard value (A): 90 +/- 3 mm (3.54 +/- 0.12 inches)
Fig. 44: Identifying TJ Boot Dimension
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSPECTION
Check the drive shaft for damage, bending or corrosion. Check the drive shaft spline part for wear or damage. Check the spider assembly for roller rotation, wear or corrosion. Check the groove inside DOJ case and TJ case for wear or corrosion. Check the boots for deterioration, dama
ge or crackin
g.
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor
Page 1899 of 3870
BJ BOOT (RESIN BOOT) REPLACEMENTRequired Special Tool:
MB991561: Boot Band Crimping Tool
1. Remove the boot bands (large and small).
2. Remove the BJ boot.
3. Wrap a plastic tape around the shaft spline, and assemble the boot band and BJ
boot.
NOTE: The boot bands cannot be reused.
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor
Page 1900 of 3870
Fig. 45: Removing Boot Band
s
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Align the center groove on the BJ boot small end with the shaft groove.
Fig. 46: Aligning Center Groove On BJ 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.
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor
Page 1901 of 3870
Fig. 47: Turning Adjusting Bolt On Special Tool MB991561
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. Position the BJ boot band (small) so that there is even clearance at either end
(A and B). 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.
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor
Page 1902 of 3870
Fig. 48: Identifying BJ Boot Band (Small) End Clearance
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. Use special tool MB991561 to crimp the boot band (small).
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 the special tool
touches the stopper.
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor
Page 1903 of 3870
Fig. 49: Crimping Boot Band (Small) Using Special Tool MB991561
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).
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor
Page 1904 of 3870
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) - C
Example: If C = 2.3 mm (0.09 inch), then W = 3.2 mm (0.13 inch).
Fig. 50: 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 drive shaft joint uses special grease. Do not
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor