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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.
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2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor
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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
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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
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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
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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
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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
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10. Fill the inside of the boot with the specified amount of the specified grease.
Specified grease: Repair kit grease
Amount to use: < FWD>: 165 +/- 10 g (5.8 +/- 0.3 ounces)
Amount to use: < AWD>: 95 +/- 10 g (3.4 +/- 0.3 ounces)
11. Align the center groove on the BJ boot big end with the BJ case groove.
Fig. 51: Aligning Center Groove On BJ Boot Big End With BJ Case
Groove
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
12. Follow the same
procedure as in ste
p 5 to ad
just the size of the o
penin
g (W) on mix old and new or different types of grease.
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor
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special tool MB991561 so that it is at the standard value.
Standard value (W): 2.9 mm (0.11 inch)
13. Position the BJ boot band (large) so that there is even clearance at either end
(D and E).
Fig. 52: Identifying BJ Boot Band (Large) End Clearance
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
14. Use special tool MB991561 to crimp the BJ boot band (large) in the same way
as in step 7 .
15. Check that the crim
ping amount
(F) of the boot ban
dis at the standard value.
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor
