Outboard
DISASSEMBLY
NOTE:
^ The front wheel driveshaft joint components are matched during manufacture and therefore cannot be interchanged with components from another front wheel driveshaft joint. Extreme care should be taken not to mix or substitute like components between front wheel driveshaft joints.
^ Vise jaw caps are made of copper, brass wood or other soft material. They are slipped over the steel jaws of the vise so as not to scratch or nick finished surfaces.
1. Clamp front wheel driveshaft joint in a vise. Do not allow vise jaws to contact the front wheel driveshaft joint boot or its front wheel driveshaft joint boot clamp.
NOTE: The vise should be equipped with jaw caps to prevent damage to any machined surfaces.
Boot Clamp Removal:
Boot Removal:
2. Cut the front wheel driveshaft joint boot clamps using side cutters and pull away from the front wheel driveshaft joint boot. After removing the front wheel driveshaft joint boot clamp, slide front wheel driveshaft joint boot down over shaft.
3. Support interconnecting shaft in a soft jaw vise and angle the CV joint to expose the inner bearing race.
4. Using a brass drift and hammer, give a sharp tap to the inner bearing race to dislodge the internal driveshaft bearing retainer circlip and separate the front wheel driveshaft joint from the interconnecting shaft. Care should be taken not to drop the front wheel driveshaft joint at separation. Remove the boot from the shaft.
5. Inspect CV joint grease for contamination.
^ If the CV joints are operating satisfactorily, and the grease does not appear to be contaminated, add grease and replace front wheel driveshaft joint boot.
^ If the lubricant appears contaminated, proceed with a complete CV joint disassembly and inspection.
6. Remove circlip located near the end of the shaft. Discard the circlip. A new circlip is supplied with both the front wheel driveshaft joint boot replacement kit and CV joint. The stop ring, located just below the circlip, should be removed only if it is damaged, worn or otherwise unserviceable.
CAUTION: DO NOT reuse circlip. Replace used circlip with a new circlip before assembly.
7. Clamp front wheel driveshaft joint in a vise. Care should be taken not to damage front wheel dust shield.
NOTE: The vise must be equipped with jaw caps to prevent damage to the shaft splines. Vise jaw caps are made of copper, brass, wood or other soft material. They are slipped over the steel jaws of the vise so as not to scratch or nick finished surfaces.
Fig. 5 CV joint ball removal:
8. Press down on inner race until it tilts enough to allow removal of the ball. A tight assembly can be tilted by tapping the inner race with wooden dowel and hammer. Do not hit the cage.
9. With the cage sufficiently tilted, remove ball from cage. Repeat this step until all six balls are removed. If balls are tight in the cage, use a screwdriver to pry the balls from cage. If a screwdriver is necessary, use an old screwdriver and blunt any sharp edges on the blade with a grinder or file.
CAUTION: Exercise care to prevent scratching or other damage to the inner race or cage spheres.
10. Pivot cage and inner race assembly until it is straight up and down in the outer race. Align cage windows with outer race lands while pivoting the bearing cage. With the cage pivoted and aligned, lift assembly from the outer race.
Fig. 12 Bearing Cage/Inner Race Assembly Removal From Outer Constant Velocity Joint:
11. Rotate inner race up and out of the cage.
ASSEMBLY
1. Apply a light coating of grease on inner and outer ball races. Install the inner race in the bearing cage.
CAUTION: Use only Constant Velocity Joint Grease (High Temp) E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A.
Fig. 15 Counterbore Positioning: Ball Groove & Window Alignment:
2. Install inner race and cage assembly in the outer race.
3. Install the assembly vertically and pivot 90° into position.
Fig. 11 CV Joint Assembly Installation Into Outer Race:
4. Align bearing cage and inner race with outer race. Tilt the inner race and cage and install a ball. Repeat this step until six balls are installed.
Boot Installation:
Boot Clamp Tool:
5. If removed, install front wheel driveshaft joint boot after removing stop ring. Install front wheel driveshaft joint boot. Make sure the front wheel driveshaft joint boot is seated in its groove and front wheel driveshaft joint boot clamp is in position. Crimp clamp using CV Boot Clamp Tool T95P-3514-A. Tighten tool through-bolt until tool is in closed position, remove tool.
6. If removed, install the stop ring. If not removed, make sure stop ring is properly seated in groove.
7. Install a new circlip, supplied with the service kit, in the groove nearest the end of shaft. Do not over-expand or twist the circlip during installation.
NOTE: To install the circlip start one end in the groove and work the circlip over the inboard CV joint stub shaft pilot bearing housing end and into the groove. This will avoid over-expanding the circlip.
CAUTION: DO NOT reuse circlip. Replace circlips before assembly.
8. Before positioning front wheel driveshaft joint boot over CV joint, pack CV joint and boot with 180 grams (6.3 oz) of the grease supplied in the service kit. Any grease remaining in tube is to be spread evenly inside front wheel driveshaft joint boot.
NOTE: Use Constant Velocity Joint Grease (High Temp) E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A on all front wheel driveshaft joints.
9. With the front wheel driveshaft joint boot held back, position CV joint on shaft and tap into position using a plastic-tipped hammer. The CV joint is fully seated when the circlip locks in the groove cut into the CV joint inner race. Check for circlip seating by attempting to pull the joint from the shaft.
10. Remove all excess grease from the CV joint external surfaces and mating front wheel driveshaft joint boot surface.
11. Position front wheel driveshaft joint boot over front wheel driveshaft joint.
12. Make sure the front wheel driveshaft joint boot is seated in its groove and front wheel driveshaft joint boot clamp is in position using CV Boot Clamp Tool.
13. Position open CV Boot Clamp Tool on clamp ear and tighten tool through bolt.
14. Tighten tool through bolt until tool is in closed position. Remove tool.