Disassembly and Assembly

NOTE: The outboard joint is not serviceable, if worn replace outboard joint and shaft as a unit.

Special Tools:

DISASSEMBLY

1. Remove the front wheel driveshaft and joint, please refer to Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair/ Service and Repair






2. Slide the two inboard clamp protectors off the boot clamps.






3. Remove the two inboard front wheel driveshaft joint boot clamp.

CAUTION: Be careful not to damage the front wheel driveshaft joint boot.






4. Slide the inboard front wheel driveshaft joint boot off the inboard Constant Velocity (CV) joint housing.






5. Remove the retaining ring.






6. Remove the inboard CV joint housing.






7. Mark the inner race and the ball cage for assembly.






8. Remove the six balls.






9. Remove the snap ring.






10. Remove the inner race and ball cage.






11. Remove the inboard front wheel driveshaft joint boot and the clamp protector.






12. Remove the two outboard boot clamps.
a. Remove the outboard clamp protectors.
b. Grip the boot clamps and peel the clamps away from the boot.






13. Remove the outboard front wheel driveshaft joint boot.
14. Inspect for contaminated grease.

NOTE: If grease is contaminated, clean and inspect the joint for wear. Replace the outboard CV joint and interconnecting shaft assembly if worn or damaged.

ASSEMBLY






1. Pack the outboard Constant Velocity (CV) joint with grease.
a. Use High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A provided in the boot kit.
b. Spread any remaining grease from service kit evenly inside the outboard boot.






2. Position the outboard front wheel driveshaft joint boot and outboard boot clamps.
a. Clean the front wheel driveshaft joint boot mounting surface.
b. Position the outboard front wheel driveshaft joint boot in the outboard CV joint grooves and position the boot clamps.






3. Use the CV Boot Clamp Installer to install the boot clamps.

NOTE: Tighten the through-bolt until the installer is in the closed position.






4. Install the two outboard clamp protectors.






5. Position the inboard clamp protector and the boot clamp on the halfshaft assembly.






6. Position the inboard front wheel driveshaft joint boot.






7. Position the ball cage on the halfshaft assembly with the tapered end toward the front wheel driveshaft joint boot.






8. Position the inner race on the halfshaft assembly with the counterbored end towards the front wheel driveshaft joint boot.

NOTE: Line up the marks made during disassembly.






9. Install the snap ring.






10. Lubricate and position the six balls.
- Use High Temp Constant Velocity Joint Grease E43Z-19590-A provided in the boot kit meeting Ford specification ESP-M1C207-A.






11. Position the clamp protector and the inboard boot clamp on the inboard CV joint housing.






12. Fill the inboard CV joint housing with 235 grams of grease.
- Use High Temp Constant Velocity Joint Grease E43Z-19590A provided in the boot kit meeting Ford specification ESP-M1C207-A.






13. Position the inboard CV joint housing and install the retaining ring.






14. Remove any excess grease from the mating surface and position the inboard front wheel driveshaft joint boot.






15. Adjust the CV joint-to-boot spacing to specification.






16. Insert a dulled screwdriver blade to relieve built up air pressure in the front wheel driveshaft joint boot.

NOTE: The air should be released only after adjusting the CV joint to boot spacing.






17. Use the CV Boot Clamp Installer to install the two inboard boot clamps.






18. Position the clamp protectors over the inboard boot clamps.
19. Install the front wheel driveshaft and joint, please refer to Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair/ Service and Repair