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Home › Mitsubishi › 2021 › Outlander PHEV LE › Repair and Diagnosis › External Pages › Different car › Section 100 (Front Axle) › Driveshaft Assembly › Outboard Joint Boot Replacement

Outboard Joint Boot Replacement

WARNING: This page is about a different car, the 2020 Mitsubishi Outlander PHEV. However, it is still accessible from the selected car via links, so may be relevant.

Required Special Tool: 

  1. Remove the boot band (large) and (small).
    NOTE: Boot band cannot be reused.
  2. Remove the boot.
  3. Apply a tape to the shaft spline area, and then incorporate the boot band and boot.
    G05394356Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  4. Install the boot, aligning with the center groove on the boot small diameter.
    G05376121Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  5. Turn the adjusting bolt of the boot band clipping tool (Special tool: MB991561) to adjust the opening dimension (W) to the standard value.

    Standard value (W): 2.9 mm (0.11 in) 

    <Over 2.9 mm (0.11 in)> Tighten the adjusting bolt. 

    <Below 2.9 mm (0.11 in)> Loosen the adjusting bolt. 

    NOTE:
    • The adjusting bolt changes W approximately 0.7 mm (0.03 in) for each rotation.
    • Do not rotate the adjusting bolt more than one rotation.
  6. Roughly position the boot band (small) at the center so that there are clearance at both ends (A and B).
    G06699748Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    G06699749Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Fix the driveshaft in an upright position, and pinch the crimping area of the boot band securely between the jaws of the special tool.
    • Be sure to compress the boot band until the special tool touches the stopper.
  7. Using the special tool to crimp the boot band (small).
    G05376124Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Check that the crimping value of the boot band (C) is equal to the standard value.

    Standard value (C): 2.4 to 2.8 mm (0.10 to 0.11 in) 

    <When the crimping value is over 2.8 mm (0.11 in)> Readjust W in step 5 according to the following expression, and then perform the operation in step 7 again. 

    W = 5.5 - C (Example: W = 2.6 for C = 2.9) 

    <When the crimping value is below 2.4 mm (0.10 in)> Remove the boot band, readjust W in step 5 according to the following expression, and then perform the operations in steps 6 and 7 again using a new boot band. 

    W = 5.5 - C (Example: W = 3.2 for C = 2.3) 

    G05904335Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  9. Check that the boot band is seated within the installation area. If it is not seated within the area, remove the band and use a new band to perform the operations shown in steps from 6 to 8.
    CAUTION:
    • The special grease is used for the joint: Do not mix old and new grease, or grease in different types.
  10. Fill the boot with the specified amount of specified grease.

    Specified grease: Repair kit grease 

    Amount used:  Refer to SERVICE SPECIFICATIONS  .

  11. Align the center groove on the resin boot large diameter with the shaft groove.
  12. As shown in step 5, using the special tool (MB991561), adjust the opening dimension (W) to the standard value.

    Standard value (W): 3.2 mm (0.13 in) 

    G05394362Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. Roughly position the boot band (large) at the center so that there are clearance at both ends (D and E).
  14. As shown in step 7, use the special tool to crimp the boot band (large).
    G06699753Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  15. Check that the crimping value of the boot band (F) is equal to the standard value.

    Standard value (C): 2.4 to 2.8 mm (0.10 to 0.11 in) 

    <When the crimping value is over 2.8 mm (0.11 in)> Readjust W in step 12 according to the following expression, and then perform the operation in step   14  again. 

    W = 5.8 - F (Example: W = 2.9 for F = 2.9) 

    <When the crimping value is below 2.4 mm (0.10 in)> Remove the boot band, readjust W in step 12 according to the following expression, and then perform the operations in steps 13 and 14 again using a new boot band. 

    W = 5.8 - F (Example: W = 3.5 for F = 2.3) 

  16. Check that the boot band is seated within the installation area. If it is not seated within the area, remove the band and use a new band to perform the operations shown in steps from 13 to 15.
    G05904338Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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