OUTBOARD JOINT BOOT (RESIN BOOT) REPLACEMENT



 1.Remove the boot bands (large and small).
note The outboard joint boot bands cannot be re-used.
2.Remove the outboard joint boot.

3.Turn the adjusting bolt on special tool boot band clipping 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.

4.Place the outboard joint 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.

5.
caution
  • Secure the drive shaft in an upright position and clamp the part of the outboard joint boot band to be crimped securely in the jaws of the special tool MB991561.
  • Crimp the outboard joint boot band until the special tool touches the stopper.
Use the special tool to crimp the outboard joint boot band (small).


6.Check that crimping amount (B) of the outboard joint boot band is at the standard value.
Standard value (B): 2.4 - 2.8 mm

    <If the crimping amount is larger than 2.8 mm>
    Readjust the value of (W) in step 3 according to the following formula, and then repeat the operation in step 5.
    W = 5.5 mm - B
    Example: If B = 2.9 mm, then W = 2.6 mm.
    <If the crimping amount is smaller than 2.4 mm>
    Remove the outboard joint boot band, readjust the value of (W) in step 3 according to the following formula, and then repeat the operations in steps 4 and 5 using a new outboard joint boot band.
    W = 5.5 mm - B
    Example: If B = 2.3 mm then W = 3.2 mm.
7.Check that the outboard joint boot band is not protruding past the place where it has been installed. If so, remove it and then repeat the operations in steps 4 to 6 using a new outboard joint boot band.
8.
caution The driveshaft joint uses special grease. Do not mix old and new grease or different types of grease.
Fill the inside of the outboard joint boot with the specified amount of the specified grease.
Specified grease: Repair kit grease 125 ± 10 g

9.Install the outboard joint boot band (large) so that there is the clearance (C) between it and the outboard joint housing is at the standard value.
Standard value (C): 0.05 - 1.55 mm
10.Follow the same procedure as in step 3 to adjust the size of the opening (W) shown on special tool MB991561 so that it is at the standard value.
Standard value (W): 3.2 mm

11.Place the outboard joint 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 outboard joint boot band (large) in the same way as in step 5.


13.Check that the crimping amount (E) of the outboard joint boot band is at the standard value.
Standard value (E): 2.4 - 2.8 mm

    <If the crimping amount is larger than 2.8 mm>
    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 - E
    Example: If E = 2.9 mm, then W = 2.9 mm.
    <If the crimping amount is smaller than 2.4 mm>
    Remove the outboard joint boot band, readjust the value of (W) in step 10 according to the following formula, and then repeat the operating in steps 11 and 12 using a new outboard joint boot band.
    W = 5.8 mm - E
    Example: If E = 2.3 mm, then W = 3.5mm.
14.Check that the outboard joint boot band is not protruding past the place where it has been installed. If so, remove it and repeat the operations in steps 11 to 13 using a new outboard joint boot band.