FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY[AJ (3.0L Duratec)]


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Disassembly

1.  Remove the drive shaft. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

2.  Secure the drive shaft in a vice using protective jaw covers.

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3.  Remove the boot band.

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4.  Slide and remove the boot.

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5.  Disconnect the tripod joint from the outer ring.

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6.  If reinstalling the tripod joint, mark the tripod joint and the drive shaft for correct installation.

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7.  Remove the snap ring.

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8.  Remove the tripod joint.

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9.  Remove the boot from the drive shaft.

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10.  Remove the two boot bands (wheel side).

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11.  Slide the boot back out of the way to expose the joint (wheel side).

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12.  Remove and dispose the retainer clip.

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13.  Slide and remove the boot (wheel side) from the drive shaft.

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Assembly

1.  Lubricate the joint (wheel side) with the BALL JOINT ADDITIVE.

Note
•  Verify that all components are clean and free of foreign material.
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2.  Install the boot.

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3.  Install a new retainer clip.

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4.  Remove any excess grease on the mating surfaces and slide the boot forward onto the joint.

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5.  Remove any excess air trapped in the boot using a cloth covered screwdriver after installing the boot correctly.

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6.  Assemble a new boot band.

(1)  Adjust clearance A by turning the adjusting bolt of the SST.
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Clearance A
2.9 mm {0.11 in}
(2)  Crimp the wheel side small boot band using the SST. Verify that clearance B is within the specification.
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•  If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
•  If clearance B is less than the specification, replace the boot band, increase clearance A of the SST, and crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}
(3)  Verify that the boot band does not protrude from the boot band installation area.
•  If it does, replace the boot band and repeat steps (2) and (3).
(4)  Fill the boot with the repair kit grease.
(5)  Adjust clearance C by turning the adjusting bolt of the SST.
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Clearance C
3.2 mm {0.13 in}
(6)  Crimp the wheel side big boot band using the SST.
(7)  Verify that clearance D is within the specification.
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•  If clearance D is more than the specification, reduce clearance C of the SST and crimp the boot again.
•  If clearance D is less than the specification, replace the boot band, increase clearance C of the SST and crimp the new boot.
Clearance D
2.4—2.8 mm {0.095—0.110 in}
(8)  Verify that the boot band does not protrude from the boot band installation area.
•  If it does, replace the boot band and repeat steps (7) and (8).

7.  Fill the boot with the repair kit grease.

8.  Position the boot (differential side).

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9.  Install the tripod joint to the drive shaft.

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(1)  Align the marks on the drive shaft and tripod joint.
(2)  Install the tripod joint to the drive shaft.

10.  Install the snap ring.

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11.  Lubricate the three tripod joint needle bearings.

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12.  Lubricate inside the tripod joint with the BALL JOINT ADDITIVE.

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13.  Position the outer ring onto the tripod.

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14.  Position the boot (differential side).

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(1)  Position the boot.
(2)  Position the boot band.

15.  Remove any excess air trapped in the boot using a cloth covered screwdriver after installing the boot correctly.

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16.  Follow the same procedures to install the two new boot bands on the opposite side.

17.  Install the drive shaft. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)