Constant Velocity Joint Boot: Service and Repair
BJ/EBJ BOOT (RESIN BOOT) REPLACEMENT
1. Remove the boot bands (large and small).
NOTE: The boot bands cannot be re-used.
2. Remove the BJ/EBJ boot.
3. Wrap a plastic tape around the shaft spline, and assemble the boot band and resin boot.
4. Align the center groove on the BJ/EBJ 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)
NOTE: The value of W will change by approximately 0.7 mm for each turn of the adjusting bolt.
NOTE: The adjusting bolt should not be turned more than once.
6. Position the BJ/EBJ boot band (small) so that there are even clearance at either end (B and C).
CAUTION: Secure the driveshaft in an upright position and clamp part of the boot band to be crimped securely in the jaws of the special tool MB991561. Crimp the boot band until the special tool MB991561 touches the stopper.
7. Use the special MB991561 tool to crimp the boot band (small).
8. Check that the crimping amount (D) of the boot band is at the standard value.
Standard value (D): 2.4 - 2.8 mm (0.10 - 0.11 mm)
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).
Remove the BJ/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 BJ/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 the operations in steps 6 to 8 using a new boot band.
CAUTION: The driveshaft 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 (BJ): 95 ± 10 g (3.4 ± 0.3 oz)
Amount to use (EBJ): 100 ± 10 g (3.5 ± 0.3 oz)
11. Align the center groove on the BJ/EBJ boot big end with the shaft groove.
12. Follow the same procedure as in step 5 to adjust the size of the opening (W) on the special tool so that it is at the standard value.
Standard value (W): 3.2 mm (0.13 inch)
13. Position the BJ/EBJ boot band (large) so that there are even clearance at either end (G and H).
14. Use the special tool MB991561 to crimp the BJ boot band (large) in the same way as in step 7.
15. Check that the crimping amount (I) of the boot band is at the standard value.
Standard value (I): 2.4 - 2.8 mm (0.10 - 0.11 inch)
W = 5.5 mm (0.22 inch) - Example: If I = 2.9 mm (0.11 inch), then W = 2.6 mm (0.10 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 the operations in steps 13 to 15 using a new boot band.