Outer Joint and Boot

NOTE: During manufacturing, CV joint components are matched. Components cannot be interchanged with another joint's components. If a joint component is defective, the entire joint should be replaced.

REMOVAL
1. Install soft vise jaw caps in vise to prevent damage to driveshaft, then position driveshaft in vise. Do not allow the vise to contact the CV joint boot or clamps.

Fig. 3 Boot Clamp Removal:

2. Using side cutting pliers, cut large boot clamp and peel away from boot. Roll boot back over driveshaft.

Fig. 4 Internal Snap Ring Removal:

3. Turn driveshaft over in vise, then angle CV joint so that inner bearing race is exposed. Using a brass drift and a hammer, give a sharp rap to inner bearing race to dislodge internal snap ring. Separate CV joint from driveshaft. Take care not to drop the joint. Remove CV boot from shaft.
4. Inspect CV joint grease for contamination. If grease appears contaminated or has a gritty feeling, inspect for worn components and replace as necessary. 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:

7. Push down on CV joint inner race until it tilts enough to allow ball removal. 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.

Fig. 6 Cage & Inner Race Removal:

9. Pivot cage and inner race assembly until it is straight up. Align cage windows with outer race lands while pivoting bearing cage, then lift out cage and inner race.

Fig. 7 Inner Race Removal & Installation:

10. Rotate inner race up and out of cage.

INSTALLATION
1. Apply light coating of Ford CV joint grease E2FZ-19590-A or equivalent on inner and outer races, then install inner race in bearing cage.

Fig. 10 Inner Race & Cage Assembly:

2. Install inner race and cage assembly in outer race.

Fig. 11 CV Joint Assembly Installation Into Outer Race:

3. Install CV joint assembly into outer race and pivot 90° into position.
4. Align bearing cage and inner race with outer race, then tilt inner race and install a ball, followed by remaining five balls.

Fig. 10 Halfshaft End Identification:

5. Determine which end of driveshaft is for outboard CV joint. The outboard joint side has a shorter end of boot groove to end of shaft dimension.
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.

Fig. 13 Exploded View Of Driveshaft Assemblies:

7. Install new circlip. Do not overexpand or twist circlip during installation. To install properly, start one end in groove and work circlip over stub shaft and into circlip groove.
8. Pack CV joint with Ford CV joint grease E2FZ-19590-A, or equivalent. Spread any remaining grease evenly inside CV boot.
9. With boot peeled back, position CV joint on driveshaft and tap into position with a plastic hammer. The joint is properly seated when the circlip locks into position. Inspect for proper retention by attempting to pull off joint.
10. Remove all excess grease from external surfaces, then position boot over joint. Ensure boot is seated in its groove, then install clamp.