I ordered the pictured boot online. The selection was a little confusing and contradictory in hindsight. The replacement has not been attempted to be installed since it appears too small of diameter and would likely spit upon installation, but not sure. The vendor when asked upon receipt and shown the pic said:
"it appears that you have not attempted to install the boot. From your picture, it appears to be the correct boot, but is of a different design than the original."

Any suggestions/comments?
Car is 62 lancer slant 6 auto

The new boot is shown inverted I believe.

The aftermarkerts are sometimes a different design.My 57 I used a leather replacment on.I drove it all the time for 7 years and still was good when I sold it.IIRC Bernbams has one of the best selections.I do know there are a few differnt ones.I have one NOS as a spare that should fit my 65 if I ever need it.Rocky

you might want to try here for a correct part
http://www.oldmoparts.com/parts-universal-joint.aspx

I assume you know the trunion has to come apart and off not just slip over the whole end. Looks real close to original ones size. Save those clamps if you can.

Actually I think you thread the new boot through the housing without disassembly. The instructions with the boot say to do it this way although I haven't actually attempted it yet. I would avoid removing the housing if there's any way possible as it's near impossible to set the cross pin precisely and I haven't found anyone to fix the one I disassembled 25 years ago. No one around here will even try to balance the unit.

You are correct you clean it then thread it thru the housing.Its a pain but can be done.It looks like it is upside down.Rocky

I had no problem finding a shop in San Diego to balance my B&T driveshaft, but that was more than 20 years ago too.

Well, if anyone knows of a shop that will do it, I'd happily ship mine to them.
Mike

I don't know if that boot will fit but, yes it goes through, not around. Cut the old boot off to give you more room. Take the tin plate off the front, shove the housing back tight against the front of the driveshaft. I pulled the balls/needle bearings so I could give them a good greasing then just stretch the boot over the cross pins onto the shaft, bring the housing forward and pull the boot through the hole, around the shaft. Not that hard.

There is a driveshaft shop here in E. Oregon that will re-install the cross pin. Not cheaply, or happily, but he will do it.

Installing the cross piece isn't anymore difficult than installing a press fit piston pin. It is not rocket science.

The old guy I watched do this change in 1963,when I was 13, must have known how to set the pin back because that's what he did. I thought he was the smartest dude in the world beside my dad and granddads.

But anyway that works.

Well as noted, the pic with the blue taped new boot is inverted, I intentionally did that to help show the difference in boot diameters. I always expected to disassemble the trunnion, then slip the boot on, then reassemble the trunnion.

I have removed the old boot, and the larger end measures approx 2.5" diameter. The replacement new boot measures approx 1.6" diameter on the large end. I see no way to stretch the boot enough to fit onto the mounting flange. I was able to remove the two straps for later reuse.

Other then that, I am still at a standstill.