Drivetrain - Front CV Boot Service Tips
TSB 10-4-1203/15/10
FRONT CONSTANT VELOCITY (CV) BOOT KITS
AVAILABLE - SERVICE TIP
FORD:
2008-2010 Fusion
MERCURY:
2008-2010 Milan
ISSUE
A Constant Velocity (CV) boot kit has been released for service. It is no longer necessary to order a complete halfshaft assembly for CV boot service. This kit is available for 2008-2010 Fusion and Milan vehicles equipped with a 3.0L engine and 2010 Fusion and Milan vehicles equipped with a 2.5L engine.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Identify which CV boot halfshafl (left or right) needs replacement.
2. Remove the halfshafl assembly per Workshop Manual (WSM), Section 205-04.
3. For the inboard CV joint, remove and discard both boot clamps.
4. Remove the inboard CV joint retaining ring. (Figure 1)
NOTE
DO NOT LET THE ROLLER BEARINGS FALL OR DAMAGE TO THE COMPONENT MAY OCCUR.
5. For the inboard CV joint, carry out the following:
a. Slide the boot away from the CV joint.
b. Using a permanent ink marker, mark the roller bearings (three (3) in total) and slots (trunnion) for proper reassembly. (Figure 2)
c. Remove the Snap Ring. (Figure 3)
d. Remove the CV joint.
e. Remove and discard the inner CV boot. (Figure 4)
NOTE
THE OUTBOARD CV JOINT IS NOT REMOVABLE FROM THE HALFSHAFT. THE BOOT MUST BE REMOVED OR INSTALLED FROM THE INBOARD CV JOINT SIDE OF THE SHAFT.
6. For the outboard CV joint, carry out the following:
a. Remove and discard the boot clamps. (Items 1 and 3. Figure 5)
b. Remove and discard the boot. (Item 2, Figure 5)
NOTE
ONCE ALL THE CV JOINT ARE APART AND UTILIZING THE CV BOOT KIT, MAKE SURE NOT TO MIX THE BOOT CLAMPS, AS THEY HAVE A DIFFERENT DIAMETER.
NOTE
THE CV BOOT KIT PROVIDES TWO (2) TYPES OF GREASE; ONE BOTTLE FOR THE INBOARD CV JOINT NGK302 AND ONE BOTTLE FOR THE OUTBOARD CV JOINT NGK509.
7. Lubricate the outboard CV joint, doing the following:
a. Pack the outboard CV joint with grease from the kit, make sure the correct outboard joint grease NGK5O9 is applied. (Figure 6)
NOTE
ONE-THIRD OF THE GREASE MUST BE INSTALLED IN THE JOINT WITH THE REMAINDER PLACED IN THE BOOT.
b. Spread the remaining grease evenly inside the boot. (Figure 6)
8. Position the boot so the rib on the boot is located in the groove of the shaft. (Figure 7)
9. Position the outboard halfshaft boot and the outboard halfshafl single ear pinch clamps. (Figure 8)
a. Position the boot. (Figure 8)
b. Position the boot clamps. (Figure 8)
10. Install the outboard CV boot single ear pinch clamps. (Figure 9-10)
a. On the 3.0L CV joint the larger outboard clamp has stamped on the band the number 6192 which is slightly smaller than the large inboard clamp which is identified by number 7392.
b. For correct results installing and crimping these clamps, use constant velocity joint boot clamp installer tool number 205-343 (T95P-3514-A). (Figure 9)
11. Position the inboard clamp and boot. Shown is the flip and lock style used only on the 2.5L CV joint. (Figure 11)
12. Install the CV joint and snap ring on the halfshaft. (Figure 3)
13. Fill the inboard CV joint housing with grease from the kit (Figure 12), make sure the correct inboard joint grease NGK302 is used.
NOTE
ONE-HALF OF THE GREASE MUST BE INSTALLED IN THE JOINT AND THE REMAINDER PLACED IN THE BOOT.
14. Reassemble the rollers in the same slot (trunnion) as previously marked. (Figure 2)
15. Position the CV housing on the CV joint. (Figure 2)
16. Install the retaining ring. (Figure 1)
17. Position the inboard halfshafl boot and clamps. Shown is the flip and lock style used only on the 2.5L CV joint. RH halfshafl is shown and LH halfshaft is similar. (Figure 13)
a. Position the boot in the housing groove.
b. Position the boot clamps.
18. Install the boot clamps. Shown is the flip and lock style used only on the 2.5L CV joint. (Figure 14)
a. On the 3.0L CV joint the larger inboard clamp has stamped on the band the number 7392 which is slightly larger than the large outboard clamp which is identified by number 6192.
b. Place the lever arm in the closed position and use a soft-faced hammer to close the tabs.
19. Install the halfshaft assembly per WSM, Section 205-04.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
100412A 2008-2010 Fusion Milan 1.5 Hrs.
2.5L, 3.0L: Replace The
Inboard And/Or Outboard
CV Boots Includes Time
To Remove And Install
The Right Front Halfshaft
(Do Not Use With Any
Other Labor Operations)
100412B 2008-2010 Fusion Milan 1.7 Hrs.
2.5L, 3.0L: Replace The
Inboard And/Or Outboard
CV Boots Includes Time
To Remove And Install
The Left Front Halfshaft
(Do Not Use With Any
Other Labor Operations)
100412C 2008-2010 Fusion Milan 2.8 Hrs.
2.5L, 3.0L: Replace The
Inboard And/Or Outboard
CV Boots Includes Time
To Remove And Install
Both Left And Right Front
Halfshafts (Do Not Use
With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A331 01
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