Disassembly and Assembly

Special Tools:

Disassembly
1. Remove the halfshaft from the vehicle.





2. CAUTION: Do not damage the boot.

Remove the boot clamps.





3. Separate the boot from the inboard CV joint housing.





4. Remove the retaining ring.





5. Remove the inboard CV joint housing.





6. Index-mark the inner race and ball cage.





7. Remove the six balls.





8. Remove the snap ring.





9. Remove the inner race and the ball cage.





10. Remove the inboard boot.





11. Remove the boot clamps.





12. Remove the outboard boot.

13. Note: If the grease is contaminated, clean and inspect the joint for wear. Install a new outboard CV joint and interconnecting shaft assembly if worn/damaged.

Check the grease for contamination.

Assembly





1. Position the outboard boot on the shaft.





2. Pack the outboard CV joint with 165 grams (5.82 ounces) of grease.
1 Use High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A provided in the boot kit.
2 Spread any remaining grease from the kit evenly inside the boot.





3. Install the outboard boot.
1 Clean the boot mounting surface.
2 Seat the boot in the joint boot groove.





4. Position the boot clamps.





5. Note: Tighten the through-bolt until the tool is in the closed position.

Using the special tool, install the two boot clamps.





6. Position the boot clamp on the shaft.





7. Position the inboard boot on the shaft.





8. Position the ball cage on the shaft with the tapered end facing the boot.





9. Note: Align the index marks.

Position the inner race on the shaft with the counterbored end facing the boot.





10. Install the snap ring.





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





12. Fill the inboard CV joint housing with 235 grams (8.29 ounces) of grease.
^ Use High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A provided in the boot kit.





13. Position the boot clamp on the inboard CV joint housing.





14. Position the inboard CV joint housing on the ball and race assembly.





15. Install the retaining ring.





16. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove.





17. Set the halfshaft assembled length to specification.





18. CAUTION: Do not damage the boot.

Insert a dull screwdriver blade under the boot to release the pressure.





19. Note: Tighten the through-bolt until the tool Is in the closed position.

Using the special tool, install the two boot clamps.
20. Install the halfshaft in the vehicle.