2005 MITSUBISHI 380 boot

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-26
BJ BOOT REPLACEMENTM1261005200394
Required Special Tool:
MB991561:Boot Band Crimping Tool
1. Remove the boot bands (large and small).
NOTE: The boot bands cannot be re-used.
2. Remove the BJ boot.
3. Wrap a plastic tape around the shaft spline, and assemble
the boot band and BJ boot.
4. Align the center groove on the BJ boot small end with the
shaft groove.
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)
Tighten the
adjusting bolt.
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 BJ boot band (small) so that there is even
clearance at either end (A and B).

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-27
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.
7. Use special tool MB991561 to crimp the boot band (small).
8. Check that the crimping amount (C) of the boot band is at
the standard value.
Standard value (D): 2.4
2.8 mm (0.09 0.11 inch)
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).
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)
D
Example: If D = 2.3 mm (0.09 inch), then W = 3.2
mm (0.13 inch).
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.
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 <3.8L>: 165
10 g (5.8 0.3 ounces)

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-28
11.Align the center groove on the BJ boot big end with the BJ
case groove.
12.Follow the same procedure as in step 5 to adjust the size of
the opening (W) on special tool 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).
14.Use special tool to crimp the BJ 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)
inch)>
Readjust the value of (W) in step 12 according to
the following formula, and then repeat the opera-
tion 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).
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.

SPECIFICATIONS
FRONT AXLE26-29
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONSM1261005400309
GENERAL SPECIFICATIONSM1261000200311
SERVICE SPECIFICATIONSM1261000300426
ITEM SPECIFICATION
Caliper assembly bolt 100
10 Nm (74 7 ft-lb)
Center bearing bracket bolt 41
4 Nm (30 3 ft-lb)
Drive shaft nut 226
29 Nm (167 21 ft-lb)
Dust cover bolt 9.0
2.0 Nm (80 17 in-lb)
Front strut nut 305
25 Nm (225 18 ft-lb)
Front wheel hub bolt 90
10 Nm (67 7 ft-lb)
Self-locking nut (lower arm ball joint connection) 65
6 Nm (48 4 ft-lb)
Self-locking nut (tie rod end connection) 29
4 Nm (21 3 ft-lb)
ITEM SPECIFICATION
Wheel bearing Type Unit ball bearing (Double-row angular contact ball
bearing)
Drive shaft Joint type Outer Birfield joint
Inner Pillow Tripod joint
ITEM STANDARD VALUE LIMIT
Wheel bearing end play mm (in)
0.05 (0.002)
Wheel bearing rotation starting torque N
m (in-lb)1.4 (12)
Setting of PTJ boot length mm
(in)3.8L 85
3 (3.35 0.12)
Opening dimension of the
special tool (MB991561) mm
(in)When the BJ boot band
(small) is crimped2.9 (0.11)
When the BJ boot band
(large) is crimped2.9 (0.11)
Crimped width of the BJ boot band mm (in) 2.4 2.8 (0.09 0.11)

SPECIFICATIONS
FRONT AXLE26-30
LUBRICANTSM1261000400412
ITEM SPECIFIED LUBRICANT QUANTITY
PTJ boot grease Repair kit grease 220
10 g (7.8 0.3 oz)
BJ boot grease Repair kit grease 165
10 g (5.8 0.3 oz)
Dust seal inner grease Repair kit grease 14
20 g (0.5 0.7 oz)
Dust seal outer grease Repair kit grease 8
12 g (0.3 0.4 oz)