BJ BOOT (RESIN BOOT) REPLACEMENT

Remove the boot bands (large and small).

NOTE: The boot bands cannot be re-used.

Remove the BJ boot.

Wrap a plastic tape around the shaft spline, and assemble the boot band and BJ boot.

Align the centre groove on the BJ boot small end with the shaft groove.

Turn the adjusting bolt on special tool boot band crimping tool (MB991561) so that the size of the opening (W) is at the standard value.

Standard value (W): 2.9 mm

<If it is larger than 2.9 mm> tighten the adjusting bolt.

<If it is smaller than 2.9 mm> loosen the adjusting bolt.

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.

Position the BJ boot band (small) so that there is even clearance at either end (A and B).

CAUTION

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.

Crimp the boot band until special tool touches the stopper.

Use the special tool to crimp the boot band (small).

Check that the crimping amount (C) of the boot band is at the standard value.

Standard value (C): 2.4 - 2.8 mm

<If the crimping amount is larger than 2.8 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 - C
Example: If C = 2.9 mm, then W = 2.6 mm.

<If the crimping amount is smaller than 2.4 mm >
Remove the BJ 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 boot band.
W = 5.5 mm - C
Example: If C = 2.3 mm, then W = 3.2 mm.

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.

CAUTION

The drive shaft joint uses special grease. Do not mix old and new or different types of grease.

Fill the inside of the boot with the specified amount of the specified grease.

Specified grease: Repair kit grease

Amount to use: 120 ± 10 g <2000-Non-Turbo>

Amount to use: 95 ± 10 g <2000-Turbo>

Amount to use: 85 ± 10 g <2400>

Align the centre groove on the BJ boot big end with the BJ case groove.

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): 2.9 mm

Position the BJ boot band (large) so that there is even clearance at either end (D and E).

Use the special tool to crimp the BJ boot band (large) in the same way as in step 7.

Check that the crimping amount (F) of the boot band is at the standard value.

Standard value (F): 2.4 - 2.8 mm

<If the crimping amount is larger than 2.8 mm >
Readjust the value of (W) in step 12 according to the following formula, and then repeat the operation in step 14.
W = 5.8 mm - F
Example: If F = 2.9 mm, then W = 2.9 mm.

<If the crimping amount is smaller than 2.4 mm >
Remove the BJ 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 BJ boot band.
W = 5.8 mm - F
Example: If F = 2.3 mm, then W = 3.5 mm.

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.


	BJ BOOT (RESIN BOOT) REPLACEMENT
	Remove the boot bands (large and small). NOTE: The boot bands cannot be re-used. Remove the BJ boot. Wrap a plastic tape around the shaft spline, and assemble the boot band and BJ boot.
	Align the centre groove on the BJ boot small end with the shaft groove.
	Turn the adjusting bolt on special tool boot band crimping tool (MB991561) so that the size of the opening (W) is at the standard value. Standard value (W): 2.9 mm <If it is larger than 2.9 mm> tighten the adjusting bolt. <If it is smaller than 2.9 mm> loosen the adjusting bolt. 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.
	Position the BJ boot band (small) so that there is even clearance at either end (A and B). CAUTION 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. Crimp the boot band until special tool touches the stopper.
	Use the special tool to crimp the boot band (small).
	Check that the crimping amount (C) of the boot band is at the standard value. Standard value (C): 2.4 - 2.8 mm <If the crimping amount is larger than 2.8 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 - C Example: If C = 2.9 mm, then W = 2.6 mm. <If the crimping amount is smaller than 2.4 mm > Remove the BJ 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 boot band. W = 5.5 mm - C Example: If C = 2.3 mm, then W = 3.2 mm. 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. CAUTION The drive shaft joint uses special grease. Do not mix old and new or different types of grease. Fill the inside of the boot with the specified amount of the specified grease. Specified grease: Repair kit grease Amount to use: 120 ± 10 g <2000-Non-Turbo> Amount to use: 95 ± 10 g <2000-Turbo> Amount to use: 85 ± 10 g <2400>
	Align the centre groove on the BJ boot big end with the BJ case groove. 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): 2.9 mm
	Position the BJ boot band (large) so that there is even clearance at either end (D and E). Use the special tool to crimp the BJ boot band (large) in the same way as in step 7.
	Check that the crimping amount (F) of the boot band is at the standard value. Standard value (F): 2.4 - 2.8 mm <If the crimping amount is larger than 2.8 mm > Readjust the value of (W) in step 12 according to the following formula, and then repeat the operation in step 14. W = 5.8 mm - F Example: If F = 2.9 mm, then W = 2.9 mm. <If the crimping amount is smaller than 2.4 mm > Remove the BJ 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 BJ boot band. W = 5.8 mm - F Example: If F = 2.3 mm, then W = 3.5 mm. 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.