Assembly
1. Slide outboard rear axle shaft outer boot on shaft.NOTE: The interconnecting shaft cannot be removed from the outboard CV joint. Outboard CV joints are serviced as assemblies, including the interconnecting shaft, rear axle shaft outer boot, axle shaft boot clamps, grease and U-washer.
2. Before positioning rear axle shaft outer boot over CV joint, pack CV joint and rear axle shaft outer boot with grease supplied in service kit as follows:
NOTE: Use Constant Velocity Joint Grease (High Temp) E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A on all outboard CV joints.
a. Pack CV joint with grease.
b. Any grease remaining in tube is to be spread evenly inside rear axle CV joint boot.
c. Total amount of grease required is 225 grams (7.94 ounces).
3. Remove any grease from rear axle shaft outer boot on CV joint mating surface before installing rear axle shaft outer boot. Position rear axle shaft outer boot on CV joint and install rear axle shaft outer boot.
4. Place axle shaft boot clamp in groove on rear axle shaft outer boot and position open CV Boot Clamp Tool T95P-3514-A on clamp ear and tighten tool through bolt.
5. Tighten tool through bolt until tool is in the closed position. Remove tool from axle shaft boot clamp.
6. Slide inboard rear axle shaft inner boot on shaft.
7. With rear axle shaft joint assembly retaining ring installed past splines, install tripod assembly with chamfered side toward interconnecting shaft.
8. Install new U-washer. Do not over-expand or twist U-washer during installation.
CAUTION: U-washer must not be reused. Replace U-washers before assembly.
NOTE: To install U-washer, start one end in the groove and work the U-washer over the stub shaft end and into the groove. This will avoid over-expanding the U-washer.
9. Compress U-washer and slide tripod assembly forward over U-washer to expose stop ring groove.
10. Move rear axle shaft joint assembly retaining ring into groove using snap-ring pliers, making sure it is fully seated in groove.
11. Install trilobe insert on inboard CV joint stub shaft pilot bearing housing.
12. Fill inboard CV joint stub shaft pilot bearing housing and rear axle shaft inner boot with grease as shown. Use Constant Velocity Joint Grease (High Temp) E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A. Total amount of grease required is 225 grams (7.94 ounces).
13. Install inboard CV joint stub shaft pilot bearing housing on tripod assembly.
14. Remove all excess grease from CV joint and boot mating surfaces. Position rear axle shaft inner boot over CV joint. Move CV joint in and out, as necessary, to adjust to length shown in the illustration.
NOTE: Before installing axle shaft boot clamp, make sure any air pressure which may have built up in rear axle shaft inner boot is relieved. Insert a dulled screwdriver blade between rear axle shaft inner boot and outer bearing race to allow trapped air to escape from rear axle shaft inner boot. The air should be released from the rear axle shaft inner boot only after adjusting to the specified dimension.
15. Make sure rear axle shaft inner boot is seated in its groove and position outer (small) axle shaft boot clamp.
16. Install large inboard axle shaft boot clamp as follows:
NOTE: A low profile axle shaft boot clamp is used on the inboard CV joint. To maintain proper clearance, reuse or replace with a low profile axle shaft boot clamp.
a. With axle shaft boot clamp boot seated in groove, place clamp over front wheel driveshaft joint boot.
b. Engage hook (C) in window.
c. Using Boot Clamp Pliers D87P-1090-A or equivalent, place pincer jaws in closing hooks (A and B).
Fig. 16 CV Boot Clamp Installation:
d. Secure axle shaft boot clamp by drawing closing hooks together. When windows (1 and 2) are above locking hooks (D and E), spring tab will press windows over locking hooks and engage axle shaft boot clamp.
17. Work the CV joint through its full range of travel at various angles. The joint should flex, extend and compress smoothly.