Mitsubishi 380. Manual - part 361

 

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Mitsubishi 380. Manual - part 361

 

 

DRIVE SHAFT ASSEMBLY

FRONT AXLE

26-26

BJ BOOT REPLACEMENT

M1261005200394

Required Special Tool:
MB991561:Boot Band Crimping Tool
1. Remove the boot bands (large and small).

NOTE: The boot bands cannot be re-used.

2. Remove the BJ boot.

3. Wrap a plastic tape around the shaft spline, and assemble 

the boot band and BJ boot.

4. Align the center groove on the BJ 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)

<If it is larger than 2.9 mm (0.11 inch)> Tighten the 

adjusting bolt.

<If it is smaller than 2.9 mm (0.11 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.

6. Position the BJ boot band (small) so that there is even 

clearance at either end (A and B).

AC102658

AC102659

AC102660

W

MB991561

STOPPER

ADJUSTING BOLT

AC

AC102661AC

BOOT

A

BOOT BAND
(SMALL)

B

PROJECTION

DRIVE SHAFT ASSEMBLY

FRONT AXLE

26-27

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 MB991561.

• Crimp the boot band until the special tool touches the 

stopper.

7. Use special tool MB991561 to crimp the boot band (small).

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

the standard value.

Standard value (D): 2.4 

− 2.8 mm (0.09 − 0.11 inch)

<If the crimping amount is larger than 2.8 mm (0.11 

inch)>
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).

<If the crimping amount is smaller than 2.4 mm (0.09 

inch)>
Remove the 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 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 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.
10.Fill the inside of the boot with the specified amount of the 

specified grease.

Specified grease: Repair kit grease

Amount to use <3.8L>: 165 

± 10 g (5.8 ± 0.3 ounces)

AC102663 AC

MB991561

AC102662

C

AD

DRIVE SHAFT ASSEMBLY

FRONT AXLE

26-28

11.Align the center groove on the BJ boot big end with the BJ 

case groove.

12.Follow the same procedure as in step 5 to adjust the size of 

the opening (W) on special tool so that it is at the standard 
value.

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

13.Position the BJ boot band (large) so that there is even 

clearance at either end (D and E).

14.Use special tool to crimp the BJ boot band (large) in the 

same way as in step 7.

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

the standard value.

Standard value (F): 2.4 

− 2.8 mm (0.09 − 0.11 inch)

<If the crimping amount is larger than 2.8 mm (0.11 

inch)>
Readjust the value of (W) in step 12 according to 
the following formula, and then repeat the opera-
tion in step 14.
W = 5.8 mm (0.23 inch) 

− F

Example: If F = 2.9 mm (0.11 inch), then W = 2.9 mm 
(0.11 inch).

<If the crimping amount is smaller than 2.4 mm (0.09 

inch)>
Remove the EBJ 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 EBJ boot band.
W = 5.8 mm (0.23 inch) 

− F

Example: If F = 2.3 mm (0.09 inch), then W = 3.5 mm 
(0.14 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 steps 13 to 15, using a new boot 
band.

AC102664 AC

AC102665AC

BOOT

PROJECTION

BOOT BAND
(LARGE)

D

E

AC102666

F

AD

SPECIFICATIONS

FRONT AXLE

26-29

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1261005400309

GENERAL SPECIFICATIONS

M1261000200311

SERVICE SPECIFICATIONS

M1261000300426

ITEM

SPECIFICATION

Caliper assembly bolt

100 

± 10 N⋅m (74 ± 7 ft-lb)

Center bearing bracket bolt 

41

± 4 N⋅m (30 ± 3 ft-lb)

Drive shaft nut

226 

± 29 N⋅m (167 ± 21 ft-lb)

Dust cover bolt

9.0 

± 2.0 N⋅m (80 ± 17 in-lb)

Front strut nut

305 

± 25 N⋅m (225 ± 18 ft-lb)

Front wheel hub bolt

90 

± 10 N⋅m (67 ± 7 ft-lb)

Self-locking nut (lower arm ball joint connection)

65 

± 6 N⋅m (48 ± 4 ft-lb)

Self-locking nut (tie rod end connection)

29 

± 4 N⋅m (21 ± 3 ft-lb)

ITEM

SPECIFICATION

Wheel bearing

Type

Unit ball bearing (Double-row angular contact ball 
bearing) 

Drive shaft

Joint type

Outer

Birfield joint

Inner

Pillow Tripod joint 

ITEM

STANDARD VALUE

LIMIT

Wheel bearing end play mm (in)

−

0.05 (0.002)

Wheel bearing rotation starting torque N

⋅m (in-lb)

−

1.4 (12)

Setting of PTJ boot length mm 
(in)

3.8L

85 

± 3 (3.35 ± 0.12)

−

Opening dimension of the 
special tool (MB991561) mm 
(in)

When the BJ boot band 
(small) is crimped

2.9 (0.11)

−

When the BJ boot band 
(large) is crimped

2.9 (0.11)

−

Crimped width of the BJ boot band mm (in)

2.4 

− 2.8 (0.09 − 0.11)

−

 

 

 

 

 

 

 

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