Constant Velocity Joint Boot: Service and Repair

REPLACEMENT
1. Remove the large and small boot bands.

NOTE: Do not reuse the boot bands.

2. Remove the Birfield Joint (B.J.) boot.





3. Install the small diameter end of the B.J. boot by so locating it as to expose only one of the grooves provided on the shaft.





4. Turn the adjusting bolt of the special tool to obtain 2.9 mm (0.114 inch) of the opening width (W).
- When width is above 2.9 mm (0.114 inch) Tighten the adjusting bolt.
- When width is below 2.9 mm (0.114 inch) Loosen the adjusting bolt.

NOTE:
- One complete turn of the adjusting bolt will change the width by approximately 0.7 mm (0.028 inch).
- Do not give more than one turn to the adjusting bolt.





5. Install the boot band (small) against the projection at the boot end to provide clearance A as shown in the illustration.





6. Using the special tool, crimp the boot band.

CAUTION:
- With the drive shaft secured vertically, pinch positively the portion to be crimped of the band between the tips of the special tool.
- Be sure to compress the boot band until the special tool handle comes in contact with the stopper.





7. Make sure that the amount of boot band crimping (B) is 2.4 - 2.8 mm (0.094 - 0.110 inch).

When Amount Of Crimping Is Above 2.8 mm (0.110 inch):
Readjust W given in (4) above to the value calculated by the following formula, and repeat work described in (6).
W = 5.5 mm (0.217 inch) - B
[Example: When B = 2.9 mm (0.114 inch), W = 2.6 mm (0.102 inch)]

When Amount Of Crimping Is Below 2.4 mm (0.094 inch):
Remove the boot band, readjust W given in (4) to the value calculated by the following formula and repeat work described in (5) and (6) by using a new boot band.
W = 5.5 mm (0.217 inch) - B
[Example: When B = 2.3 mm (0.091 inch), W = 3.2 mm (0.126 inch)]

8. Make sure that the boot band does not protrude from the band mounting area. If the band protrude, replace it with a new band and repeat work described in (5) through (7).
9. Pack the boot with Grease in repair kit with 155 grams (5.47 oz.).





10. Install the boot with a clearance of 0.1 - 1.55 mm (0.004 - 0.061 inch) (C) provided between the large diameter end of the boot and the shoulder of B.J. housing.
11. Adjust the width of opening in the special tool (W) to 3.2 mm (0.126 inch) in the same manner as described in (4).





12. Install the boot band (large) against the projection at the, boot end to provide clearance D as shown in the illustration.
13. Crimp the boot band (large) with the special tool in the same manner as described in (6) above.





14. Make sure that the amount of boot band crimping is within the range of 2.4 - 2.8 mm (0.094 - 0.110 inch) (E).

When Amount Of Crimping Is Above 2.8 mm (0.110 inch):
Readjust W given in (11) to a value obtained by the following formula and repeat work described in (13) above.
W = 5.8 mm (0.228 inch)- E
[Example: When E = 2.9 mm (0.114 inch), W = 2.9 mm (0.114 inch)]

When Amount Of Crimping Is Below 2.4 mm (0.094 inch):
Remove the boot band, readjust W given in (11) to a value calculated by the following formula and repeat work described in (12) and (13) by using a new boot band.
W = 5.8 mm (0.228 inch)- E
[Example: When E = 2.3 mm (0.091 inch), W = 3.5 mm (0.138 inch)]

15. Make sure that the boot band does not protrude from its mounting area. If the band protrudes, replace it with a new band and repeat work described in (12) through (14).