With AX4S Transaxle
Inboard CV Joint (Part 1 Of 2):
Inboard CV Joint (Part 2 Of 2):
DISASSEMBLY
CAUTION: The RH inboard CV joint stub shaft pilot bearing housing requires a reusable, low profile front wheel driveshaft joint boot clamp. A special tool is required to remove and install the front wheel driveshaft joint boot clamp. Use Boot Clamp Pliers D87P-1090-A or equivalent.
NOTE: The inboard CV joint tripod is permanently retained to the interconnecting shaft. The service CV joint includes shaft and front wheel driveshaft joint boot. Front wheel driveshaft joint boot or front wheel driveshaft and joint replacement will require removal of front wheel driveshaft joint and outboard front wheel driveshaft joint boot.
1. Remove right side inboard front wheel driveshaft joint boot clamp by engaging pincer jaws in closing hooks (A and B) and drawing hooks together. Disengage windows and locking hooks and remove front wheel driveshaft joint boot clamp. For left side inboard front wheel driveshaft joint boot clamp, cut and remove both.
Housing/Spider Separation:
2. Slide inboard CV joint outer race off tripod.
3. When replacing damaged front wheel driveshaft joint boots, the grease should be checked for contamination. If the CV joints are operating satisfactorily, and the grease does not appear to be contaminated, add grease and replace the front wheel driveshaft joint boot. If the grease appears contaminated, proceed with a complete CV joint disassembly and inspection.
4. Remove stop ring and driveshaft bearing retainer circlip.
NOTE: If further disassembly is required, first remove outboard front wheel driveshaft joint and front wheel driveshaft joint boot.
5. Slide inboard front wheel driveshaft joint boot off interconnecting halfshaft.
6. Remove trilobe insert, if equipped, from inboard CV joint housing. Remove grease from outer race and inspect outer race and tripod assembly.
ASSEMBLY
1. Install front wheel driveshaft joint boot on interconnecting halfshaft. Position front wheel driveshaft joint boot to allow for inboard CV joint housing installation.
2. If equipped, install trilobe insert on inboard CV joint housing. Position in groove on outer race.
3. Using Constant Velocity Joint Grease (High Temp) E43Z-19590-A or equivalent meeting Ford specification ESP-MIC207-A, fill inboard CV joint housing and spread remaining grease evenly inside front wheel driveshaft joint boot. Total fill is 250 grams (9 oz).
4. Install front wheel driveshaft joint on tripod assembly
Halfshaft Assembled Length Specifications:
5. Remove all excess grease from CV joint external surfaces and mating front wheel driveshaft joint boot surface. Position front wheel driveshaft joint boot over inboard CV joint housing making sure front wheel driveshaft joint boot is seated in groove. Move inboard CV joint housing in and out, as necessary, to adjust to length shown the Halfshaft Assembled Length Specifications image.
Fig. 16 CV Boot Clamp Installation:
6. Install the RH inboard large clamp as follows:
a. With front wheel driveshaft joint 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).
d. Secure front wheel driveshaft joint 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 front wheel driveshaft joint boot clamp.
For LH inboard large front wheel driveshaft joint boot clamp, locate clamp tabs in slots. Make front wheel driveshaft joint boot clamps as tight as possible by hand.
CAUTION: All vehicles require a reusable low profile large front wheel driveshaft joint boot clamp on the RH inboard CV joint housing.
NOTE: Before installing front wheel driveshaft joint boot clamp, make sure any air pressure which may have built up in front wheel driveshaft joint boot is relieved. Insert a dulled screwdriver blade between front wheel driveshaft joint boot and inboard CV joint housing to allow trapped air to escape from front wheel driveshaft joint boot. The air should be released from the front wheel driveshaft joint boot only after adjusting to dimension shown in the Halfshaft Assembled Length Specifications image.
7. Position CV Boot Clamp Tool T95P-3514-A on clamp ear and tighten tool through bolt until tool is in closed position.
8. On RH side inboard CV joint stub shaft pilot bearing housing, install a new circlip, supplied with service kit, in groove nearest end of shaft by starting one end in groove and working circlip over stub shaft end and into groove.
CAUTION: Do not over-expand or twist circlip during installation. DO NOT reuse circlips. Replace with new circlips before assembly.
9. Work the CV joint through its full range of travel at various angles. The joint should flex, extend and compress smoothly.