Constant Velocity Joint Boot: Service and Repair
BJ BOOT REPLACEMENT
1. Remove the boot bands (large and small).
NOTE: The BJ boot bands cannot be re-used.
2. Remove the BJ boot.
3. Turn the adjusting bolt on the special tool MB991561 so that the size of the opening (W) is at the standard value.
Standard value (W): 2.9 mm (0.12 inch)
Tighten the adjusting bolt.
If it is smaller than 2.9 mm (0.12 inch)>
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.
4. Place the BJ boot band (small) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (A) in the illustration.
CAUTION:
^ Secure the driveshaft in an upright position and clamp the part of the BJ boot band to be crimped securely in the jaws of the special tool MB991561.
^ Crimp the BJ boot band until the special tool MB991561 touches the stopper.
5. Use special tool MB991561 to crimp the BJ boot band (Small).
6. Check that crimping amount (B) of the BJ boot band is at the standard value
Standard value (B): 2.4 - 2.8 mm (0.10 - 0.11 inch)
Readjust the value of (W) in step 4 according to the
following formula, and then repeat the operation in step 6.
[W = 5.5 mm (0.22 inch) - B]
Example: If B = 2.9 mm (0.11 inch), then W = 2.6 mm (0.10 inch).
If the crimping amount is smaller than 2.4 mm (0.09 inch)>
Remove the BJ boot band, readjust the value of (W) in step 4 according to the following formula, and then repeat the operations in steps 5 and 6 using a new BJ boot band.
[W = 5.5 mm (0.22 inch) - B]
Example: If B = 2.3 mm (0.10 inch), then W = 3.2 mm (0.13 inch).
7. Check that the BJ boot band is not sticking out past the place where it has been installed If the BJ boot band is sticking out, remove it and then repeat the operations in steps 4 to 6 using a new BJ boot band
CAUTION: The driveshaft joint uses special grease. Do not mix old and new grease or different types of grease.
8. Fill the inside of the BJ boot with the specified amount of the repair kit grease
Grease quantity:
<2.4L ENGINE> 110 ± 10 grams (3.9 ± 0.4 ounces)
<3.0L ENGINE> 120 ± 10 grams (4.2 ± 0.4 ounces)
9. Install the BJ boot band (large) so that clearance (C) between it and the BJ housing is at the standard value
Standard value (C): 0.1 - 1.55 mm (0.004 - 0.061 inch)
10. Follow the same procedure as in step 3 to adjust the size of the opening (W) on special tool MB991561 so that it is at the standard value.
Standard value (W): 3.2 mm (0.13 inch)
11. Place the BJ boot band (large) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (D) in the illustration.
12. Use special tool MB991561 to crimp the BJ boot band (large) in the same way as in step 5.
13. Check that the crimping amount (E) of the BJ boot band is at the standard value and that the crimping amount (F) of the BJ boot band is at the limited value.
Standard value (E): 2.4 - 2.8 mm (0.10 - 0.11 inch)
Limited value (F): 9.5 mm (0.40 inch)
If the crimping amount is larger than 2.8 mm (0.11 inch)>
Readjust the value of (W) in step 10 according to the following formula, and then repeat the operation in step 12.
[W = 5.8 mm (0.23 inch) - E]
Example: If E = 2.9 mm (0.11 inch), then W = 2.9 mm (0.11 inch).
Remove the BJ boot band, readjust the value of (W) in step 10 according to the following formula, and then repeat the operations in steps 11 and 12 using a new BJ boot band.
[W = 5.8 mm (0.23 inch) - E]
Example: If E = 2.3 mm (0.10 inch) then W = 3.5 mm (0.15 inch).
14. Check that the BJ boot band is not sticking out past the place where it has been installed. If the BJ boot band is sticking out, remove it and then repeat the operations in steps 11 to 13 using a new BJ boot band.