Mitsubishi Galant. Manual — part 483

DRIVE SHAFT ASSEMBLY

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FRONT AXLE

26-21

>>F<< TJ CASE/INNER SHAFT ASSEMBLY INSTALLATION
1. Apply the specified grease to the inner shaft serration, and

then press the inner shaft assembly into the TJ case.

CAUTION

The driveshaft joint uses special grease. Do not mix old
and new or different types of grease.
2. Fill the TJ case with repair kit grease and insert the

driveshaft, and then refill the TJ case with repair kit grease.

Grease quantity:
<2.4L ENGINE> 100

±±±±

10 g (3.5

±±±±

0.4 oz)

<3.0L ENGINE> 105

±±±±

10 g (3.7

±±±±

0.4 oz)

NOTE: The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the boot.

>>G<< TJ BOOT BAND(SMALL)/TJ BOOT BAND(LARGE)
INSTALLATION
1. Position the TJ outer race so that the distance between the

boot bands is at the standard value.

Standard value (A): 85

±±±±

3 mm(3.3

±±±±

0.12 inch)

2. Remove part of the TJ outer race to release the air pressure

inside the boot.

BJ BOOT (RESIN BOOT) REPLACEMENT

M1261005200059

1. Remove the boot bands (large and small).

NOTE: The BJ boot bands cannot be re-used.

2. Remove the BJ boot.

AC001171

TJ CASE

AB

INNER
SHAFT
ASSEMBLY

AC001172

AC001173AB

A

ACX00982 AB

DRIVE SHAFT ASSEMBLY

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FRONT AXLE

26-22

3. Turn the adjusting bolt on special tool MB991561 so that the

size of the opening (W) is at the standard value.

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.

Standard value (W):

••••

2.9 mm (0.12 inch)

<If it is larger than 2.9 mm (0.12 inch)>

••••

Tighten the adjusting bolt.

<If it is smaller than 2.9 mm (0.12 inch)>

••••

Loosen the adjusting bolt.

4. Place the BJ 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.

CAUTION

•

Secure the driveshaft in an upright position and clamp
the part of the BJ boot band to be crimped securely in
the jaws of the special tool.

•

Crimp the BJ boot band until the special tool touches
the stopper.

5. Use special tool MB991561 to crimp the BJ boot band

(small).

ACX00993AB

STOPPER

ADJUSTING BOLT

(W)

MB991561

AC003161AB

BJ BOOT BAND
(SMALL)

BJ BOOT

A

PROJECTION

ACX00995AB

MB991561

DRIVE SHAFT ASSEMBLY

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6. Check that crimping amount (B) of the BJ boot band is at the

standard value.

Standard value (B):

••••

2.4

−−−−

2.8 mm (0.10

−−−−

0.11 inch)

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

inch)>

••••

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 (0.22 inch)

−−−−

B

••••

Example: If B = 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 BJ 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 BJ boot band.

••••

W = 5.5 mm (0.22 inch)

−

−

−

−

B

••••

Example: If B = 2.3 mm (0.10 inch) then W = 3.2
mm (0.13 inch).

7. Check that the BJ 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 BJ boot band.

CAUTION

The driveshaft joint uses special grease. Do not mix old
and new grease or different types of grease.
8. Fill the inside of the BJ boot with repair kit grease.

Grease quantity:

••••

<2.4L ENGINE> 110

±±±±

10 g (3.9

±±±±

0.4 oz)

••••

<3.0L ENGINE> 120

±±±±

10 g (4.2

±±±±

0.4 oz)

9. Install the BJ boot band (large) so that clearance (C)

between it and the BJ housing is at the standard value.

Standard value (C): 0.1

−−−−

1.55 mm (0.004

−−−−

0.061 inch)

ACX00996AC

B

ACX00993AB

STOPPER

ADJUSTING BOLT

(W)

MB991561

AC003612 AB

C

DRIVE SHAFT ASSEMBLY

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10.Follow the same procedure as in step 3 to adjust the size of

the opening (W) on special tool MB991561 so that it is at the
standard value.

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

11.Place the BJ 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 BJ boot band

(large) in the same way as in step 5.

13.Check that the crimping amount (E) of the BJ boot band is at

the standard value.

Standard value (E):

••••

2.4

−−−−

2.8 mm (0.10

−−−−

0.11 inch)

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

inch)>

••••

Readjust the value of (W) in step 10 according
to the following formula, and then repeat the
operation in step 12.

••••

W = 5.8 (0.23 inch) mm

−−−−

E

••••

Example: If E = 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 BJ 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 BJ boot band.

••••

W = 5.8 (0.23 inch) mm

−−−−

E

••••

Example: If E = 2.3 mm (0.10 inch), then W =
3.5mm (0.14 inch).

14.Check that the BJ 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 BJ boot band.

ACX00993AB

STOPPER

ADJUSTING BOLT

(W)

MB991561

AC003613 AB

BJ BOOT BAND

PROJECTION

BJ BOOT

D

AC003158

E