Procedures
CAUTIONS:^ Servicing the BJ is limited only to replacement of the boot. Never disassemble the BJ. The BJ cannot be repaired. If the BJ is worn-out or damaged, it must be replaced.
^ The BJ boot can be installed, even though the diameter of the small end of the boot is smaller than the diameter of the axle shaft. The boot will stretch to fit the shaft.
BIRFIELD JOINT (BJ) BOOT REPLACEMENT
1. The drive shaft (front axle) must be removed from the vehicle to replace the BJ boot. Refer to section 26, Front Axle, in the Volume 1 Service Manual for the vehicle you are working on for front axle removal procedures.
2. Remove both BJ clamps.
NOTE:
The clamps cannot be reused.
3. Remove the BJ boot.
4. Install the small end of the new BJ boot onto the axle shaft so that one groove on the axle is exposed as shown in the illustration.
5. Rotate the adjustment screw on the special tool so the clearance stop opening dimension (W on the illustration) is 2.9 mm.
NOTE:
If (W) is more than 2.9 mm, turn the adjustment screw clockwise. If (W) is less than 2.9 mm, turn the screw counterclockwise.
6. Install the small boot clamp so that it rests against the ridge on the small end of the boot as shown in the illustration. When installed properly, there will be clearance at position A as illustrated.
7. Using the special tool, MB991561, crimp the small boot clamp.
NOTE:
^ Secure the drive axle shaft in an upright position and hold the clamp securely in the jaws of the tool.
^ Crimp the clamp firmly until the tool comes to rest against its clearance stop.
8. Check to make sure the crimped distance, marked (B) in the illustration, is between 2.4-2.8 mm.
NOTE:
^ If (B) is more than 2.8 mm, readjust the tool clearance opening dimension, (W) in Step 5, by using the following formula:
W = 5.5 - B
Example: When (B) = 2.9, then 5.5 - B(2.9) = W(2.6)
You would need to adjust the tool (W) dimension to 2.6 mm, then re-crimp the clamp.
If (B) is less than 2.4 mm, remove the clamp, readjust (W) on the tool as shown in Step 5 using the following formula. Then, install a new clamp and repeat Steps 6 and 7.
W = 5.5 - B
Example: When (B) = 2.3, then 5.6 - B (2.3) = W (3.2)
You would adjust the tool (W) dimension to 3.2 mm, then crimp the newly installed clamp.
9. After crimping the clamp, make sure it is seated into the proper recess in the boot, and is not covering any other area on the boot. If it is not in the proper place, remove it and install another clamp by repeating Steps 6 through 8.
10. Fill the boot with the specified amount of grease provided with the boot kit.
11. Install the large end of the boot onto the BJ housing so the clearance (C) between the boot and the stepped portion of the housing is 0.1 to 1.55 mm.
12. Rotate the adjustment screw on the special tool so the clearance stop opening dimension (W on the illustration) is 3.2 mm.
NOTE:
If (W) is more than 3.2 mm, turn the adjustment screw clockwise. If (W) is less than 3.2 mm, turn the screw counterclockwise.
13. Place the large boot clamp so it contacts the ridge at the end of the boot. Make sure there is clearance between the boot and the BJ housing as shown in area (D) of the illustration.
14. Using the special tool, crimp the large clamp.
NOTE:
^ Secure the drive axle shaft in an upright position and hold the clamp securely in the jaws of the tool.
^ Crimp the clamp firmly until the tool comes to rest against its clearance stop.
15. Check to make sure the crimped distance, marked (E) in the illustration, is between 2.4-2.8 mm.
NOTE:
If (E) is more than 2.8 mm, readjust the tool clearance opening dimension, (W) in Step 5, by using the following formula:
W = 5.8 - E
Example: When (E) = 2.9, then 5.8- E(2.9) = W(2.9)
You would need to adjust the tool (W) dimension to 2.9 mm, then re-crimp the clamp.
If (E) is less than 2.4 mm remove the clamp, readjust the (W) on the tool as shown in Step 5 using the following formula. Then, install a new clamp repeating Steps 13 and 14.
W = 5.8 - E
Example: When (E) = 2.3, then 5.8 - E (2.3) = W (3.5)
You would adjust the tool (w) dimension to 3.2 mm, then crimp the newly installed clamp.
16. After crimping the clamp, make sure it is seated into the proper recess in the boot and is not covering any other area on the boot. If it is not in the proper place, remove it and install a new clamp, then repeat Steps 13 through 15.