Inboard

Disassembly

Fig. 14 CV Joint Identification:

These models use two different types of inboard CV joints and boots, Fig. 14. The first one is of a conventional boot design that uses a crimped can on the large end. The other is a tri-lobe design CV joint that does not require a crimped can on the large end. Although both designs are similar, they are not interchangeable.
1. Cut and remove both large and small boot clamps from CV joint, then slide boot back on shaft. All right side inboard CV joints use a re-usable low profile large boot clamp. Do not cut this clamp as it will be re-used.
2. Slide outer race off tripod assembly. Inspect CV joint grease for contamination by rubbing a small amount between two fingers. Any gritty feeling indicates contamination. If grease is contaminated, proceed with disassembly. If grease is not contaminated and joint was operating satisfactorily, add grease and replace boot.
3. Using suitable snap ring pliers, slide stop ring back on shaft.
4. Slide tripod assembly back on shaft to provide clearance to circlip, then remove circlip, tripod assembly and boot.

Assembly

1. Install CV boot on shaft. Ensure boot small end is seated properly in halfshaft groove, then tighten small end clamp.
2. Install tripod assembly on shaft with chamfered side toward stop ring, then install new circlip. Circlips cannot be re-used. They must be replaced with new ones.
3. Slide tripod assembly forward to expose stop ring groove, then slide stop ring into position. Ensure stop ring is fully seated in groove.
4. On models with conventional design boots, Fig. 14, fill CV joint outer race with 3.5 ounces and CV boot with 2.5 ounces of Ford CV joint grease-high temperature No. E43Z-19590-A or equivalent. On models with tri-lobe design boots, Fig. 14, fill CV joint outer race with 4.4 ounces and CV boot with 4.4 ounces of Ford CV joint grease-high temperature No. E43Z-19590-A or equivalent.
5. Install outer race over tripod assembly, then position boot over outer race. Ensure boot is properly seated in its groove.

Fig. 15 Halfshaft Assembled Length:

Fig. 16 CV Boot Clamp Installation:

6. Remove excess grease from boot exterior. Move CV joint in or out as necessary to adjust halfshaft to length as shown in Fig. 15. After halfshaft length has been determined, expel any built up air pressure from boot by inserting a dull screwdriver between boot and outer bearing and allowing air to escape.
7. Install large boot clamp with suitable crimping pliers tool No. D87P-1098-A or equivalent.
8. Right side inboard CV joints use a re-usable low profile large boot clamp. Do not install clamp with crimping pliers. To install boot proceed as follows:
a. With boot seated in groove, install clamp.
b. Engage hook (C) in window, Fig. 16.
c. Using low profile boot clamp installation pliers tool No. D87P-1090-A or equivalent, place pincer jaws in closing hooks (A and B).
d. Pull closing hooks together, when 1 and 2 are above locking hooks (D and E) spring tab will press window over locking hooks and engage clamp.
9. Install new circlip. 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.