Outboard

DISASSEMBLY
1. Clamp the front wheel driveshaft and joint in a soft jaw vise. Do not allow the vise to contact the front wheel driveshaft joint boot or the front wheel driveshaft joint boot clamps. The vise should be equipped with jaw caps to prevent damage to any machined surfaces.

NOTE: The front wheel driveshaft and joint components are matched during manufacture and cannot be interchanged with components from another front wheel driveshaft and joint. Extreme care should be taken not to mix or substitute front wheel driveshaft and joint components.





2. Remove the outboard large front wheel driveshaft joint boot clamp. Side cutters can be used to cut the front wheel driveshaft joint boot clamp. After removing the front wheel driveshaft joint boot clamp, roll back the front wheel driveshaft joint boot.

NOTE: After cutting the front wheel driveshaft joint boot clamp, peel it away from the front wheel driveshaft joint boot in the direction of the arrow.





3. If this procedure is being performed only to replace a damaged front wheel driveshaft joint boot, the grease should be checked for contamination. The grease can be checked for contamination by rubbing it between two fingers. Any gritty feeling indicates a contaminated front wheel driveshaft joint.
^ A contaminated front wheel driveshaft joint must be completely disassembled, cleaned and inspected.
^ If the grease is not contaminated and the front wheel driveshaft joint has been operating satisfactorily, replace only the front wheel driveshaft joint boot and add the required lubricant.
4. Support halfshaft and angle front wheel driveshaft joint to expose inner bearing race.





5. Using a brass drift and hammer, give a sharp tap to the inner bearing race to dislodge internal driveshaft bearing retainer circlip and separate front wheel driveshaft joint from halfshaft. Care should be taken not to drop front wheel driveshaft joint at separation.





6. Remove the small front wheel driveshaft joint boot clamp and remove the front wheel driveshaft joint boot from the front wheel driveshaft and joint.

Boot Installation:

ASSEMBLY
1. Cover the front wheel driveshaft and joint splines with tape and install the front wheel driveshaft joint boot and small front wheel driveshaft joint boot clamp. Tighten the clamp securely, but not to the point where clamp bridge is cut or the boot is damaged.

NOTE: The front wheel driveshaft and joint must be lubricated with Ford High Temperature Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford Specification ESP-M1C207-A.

2. Install a new driveshaft bearing retainer circlip on the halfshaft.
3. Pack front wheel driveshaft joint boot with Ford High Temperature Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford Specification ESP-M1C207-A.





4. With front wheel driveshaft joint boot held back, position front wheel driveshaft joint on shaft and tap into position using a plastic faced hammer.
5. Remove all excess grease from CV joint external surfaces and boot sealing surfaces.
6. Position front wheel driveshaft joint boot over front wheel driveshaft joint. Install front wheel driveshaft joint boot clamp. Tighten front wheel driveshaft joint boot clamp securely.