Constant Velocity Joint Boot: Service and Repair
DisassemblyFig. 3 Boot Clamp Removal:
Fig. 6 Separating Constant Velocity Joint From Shaft:
During manufacture, CV joints components are matched and cannot be interchanged with components of other CV joint. If a CV joint component is defective, the entire CV joint should be replaced.
1. Install soft vise jaw caps in vise to prevent damage to halfshaft, then position halfshaft in vise. Do not allow the vise to contact the CV joint boot or clamps.
2. Using suitable side cutting pliers, cut large boot clamp and peel away from boot. Roll boot back over halfshaft, Fig. 3.
3. Turn halfshaft over in vise, then angle CV joint so that inner bearing race is exposed, Fig. 4. Using suitable brass drift and hammer, give a sharp rap to inner bearing race to dislodge internal snap ring. Separate CV joint from halfshaft. Take care not to drop the CV joint. Remove CV boot from shaft.
4. Inspect CV joint grease for contamination. If grease is contaminated, proceed with disassembly. If grease is not contaminated and joint was operating satisfactorily, add grease and replace boot.
5. Remove and discard circlip from end of shaft. Inspect stop ring located below circlip, if it is worn or damaged, replace it.
6. Clamp CV joint stub axle in vise with soft vise jaw caps. Be careful not to damage dust seal.
Fig. 5 CV joint ball removal:
Fig. 6 Cage & Inner Race Removal:
Fig. 7 Inner Race Removal & Installation:
7. Push down on CV joint inner race until it tilts enough to allow ball removal, Fig. 5. If inner race is tight, it can be tilted by tapping inner race with wooden dowel and hammer. Do not hit cage.
8. Remove balls from cage. If balls are tight, use blunt screwdriver to pry balls from cage.
9. Pivot cage and inner race assembly until its straight up, Fig. 6. Align cage windows with outer race lands while pivoting bearing cage, then lift out cage and inner race.
10. Rotate inner race up and out of cage, Fig. 7.
Inspection
During manufacture, CV joints components are matched and cannot be interchanged with components of other CV joint. If a CV joint component is defective, the entire CV joint should be replaced.
Inspect all parts. If any parts are cracked, broken, severely pitted, worn or otherwise unserviceable, replace CV joint. If any parts appear polished, do not replace CV joint as this is a normal condition.
Assembly
Fig. 8 Inner Race & Cage Assembly:
Fig. 9 Inner Race & Cage Assembly To Outer Race Installation:
Fig. 10 Halfshaft End Identification:
Fig. 11 Exploded View Of Halfshaft Assemblies:
1. Apply light coating of Ford constant velocity joint grease No. E2FZ-19590-A or equivalent on inner and outer races, then install inner race in bearing cage, Fig. 7.
2. Install inner race and cage assembly in outer race land, Fig. 8.
3. Install CV joint assembly into outer race and pivot 90° into position, Fig. 9.
4. Align bearing cage and inner race with outer race, then tilt inner race and install a ball, followed by remaining five balls.
5. Determine which end of halfshaft is for outboard CV joint. The outboard joint side has a shorter end of boot groove to end of shaft dimension, Fig. 10.
6. Install CV joint boot and small boot clamp. If stop ring was removed, install at this time. If stop ring was not removed, ensure it is seated properly in groove.
7. Install new circlip, Fig. 11. Do not over expand or twist the circlip during installation. To install properly, start one end in the groove and work the circlip over the stub shaft and into the circlip groove.
8. Pack CV joint with Ford CV joint grease No. E2FZ-19590-A or equivalent. Correct quantity is 3.52 ounces on 1989 models, or 3.17 ounces on 1990 models. Any remaining grease is to be spread evenly inside CV boot.
9. With boot peeled back, position CV joint on halfshaft and tap into position with suitable plastic hammer. The CV joint is properly seated when the circlip locks into position. Check for proper retention by attempting to pull off CV joint.
10. Remove all excess grease from CV external surfaces, then position boot over CV joint. Ensure boot is seated in its groove and install clamp.