BJ Boot Replacement

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

Remove the boot bands (large and small).
NOTE: The BJ boot bands cannot be re-used.
Remove the BJ boot.

Fig 1: Removing BJ Boot Bands
Courtesy of DAIMLERCHRYSLER CORPORATION
Turn the adjusting bolt on the special tool MB991561 so that the size of the opening (W) is at the standard value.
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.

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.

Fig 2: Turning Adjusting Bolt On Special Tool
Courtesy of DAIMLERCHRYSLER CORPORATION
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.

Fig 3: Placing BJ Boot Band (Small)
Courtesy of DAIMLERCHRYSLER CORPORATION
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 special tool MB991561.
- Crimp the BJ boot band until the special tool touches the stopper.
Use the special tool to crimp the BJ boot band (small).

Fig 4: Crimping BJ Boot Band (Small)
Courtesy of DAIMLERCHRYSLER CORPORATION
Check that crimping amount (B) of the BJ boot band is at the standard value.

Fig 5: Checking Crimping Amount Of BJ Boot Band
Courtesy of DAIMLERCHRYSLER CORPORATION

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 4 according to the following formula, and then repeat the operation in Step 6 .

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 4 according to the following formula, and then repeat the operations in Steps 5 and 6 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).

Fig 6: Turning Adjusting Bolt On Special Tool
Courtesy of DAIMLERCHRYSLER CORPORATION
Check that the BJ boot band is not sticking out past the place where it has been installed. If the BJ boot band is sticking out, 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.
Fill the inside of the BJ boot with the specified amount of the 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)
Install the BJ boot band (large) so that clearance (C) between it and the BJ housing is at the standard value.
Standard value (C): 0.10 - 1.55 mm (0.004 - 0.061 inch)

Fig 7: Checking Clearance Between BJ Boot Band And BJ Housing
Courtesy of DAIMLERCHRYSLER CORPORATION
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)

Fig 8: Turning Adjusting Bolt On Special Tool
Courtesy of DAIMLERCHRYSLER CORPORATION
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.
Use special tool MB991561 to crimp the BJ boot band (large) in the same way as in Step 5.

Fig 9: Placing BJ Boot Band (Large)
Courtesy of DAIMLERCHRYSLER CORPORATION
Check that the crimping amount (E) of the BJ boot band is at the standard value and that the crimping amount (F) of the BJ boot band is at the limited value.
Standard value (E): 2.4 - 2.8 mm (0.10 - 0.11 inch)

Limited value(F): 9.5 mm (0.40 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 mm (0.23 inch) - 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 operations in Steps 11 and 12 using a new BJ boot band.

W = 5.8 mm (0.23 inch) - E

Example: If E = 2.3 mm (0.10 inch) then W = 3.5 mm (0.15 inch).

Fig 10: Checking Crimping Amount Of BJ Boot Band
Courtesy of DAIMLERCHRYSLER CORPORATION
Check that the BJ boot band is not sticking out past the place where it has been installed. If the BJ boot band is sticking out, remove it and then repeat the operations in Steps 11 to 13 using a new BJ boot band.