Halfshaft-Outboard

Halfshaft-Outboard





Special Tool(s)

Disassembly

CAUTION: Never attempt to mix or substitute components from other halfshafts. The manufacturer matches the halfshaft assembly components during production.





1. CAUTION: Do not allow the vise jaws to contact the front wheel driveshaft joint boot or the clamp. Use a vise equipped with soft jaws or wood blocks.

Clamp the halfshaft assembly in a vise.





2. Remove the clamps.





3. Separate the front wheel driveshaft joint boot from the front wheel driveshaft joint (3B413).
4. Check the CV joint grease for contamination by rubbing it between two fingers. Any gritty feeling indicates contamination.
^ If the grease is contaminated/additional disassembly is necessary, proceed as follows.





5. CAUTION: Do not allow the front wheel driveshaft joint to fall.

Using a brass drift and a hammer, separate the front wheel driveshaft joint from the interconnecting shaft.
^ Give a sharp tap to the inner bearing race to dislodge the circlip.





6. CAUTION: Do not reuse the circlip.

NOTE: Install a new stop ring, located just below the circlip, only if the stop ring is damaged/worn, or additional halfshaft disassembly is necessary.

Remove and discard the circlip. Remove the stop ring if damaged/worn, or additional halfshaft disassembly is necessary.
7. If necessary, remove the boot from the shaft.





8. Position the special tool on a press bed, and place the front wheel driveshaft joint on the special tool.





9. Press the front brake anti-lock sensor indicator (2C182) off of the front wheel driveshaft joint.





10. CAUTION: Use a vise equipped with soft jaws or wood blocks.

Clamp the front wheel driveshaft joint in a vise.








11. Press down on the inner race until it pivots enough to allow removal of a ball.

^ CAUTION: Do not hit the ball cage.

To pivot a tight assembly, tap on the inner race with a wooden dowel and hammer.








12. CAUTION: Do not scratch or damage the Inner race and ball cage.

Remove the remaining balls.
^ If the balls are tight in the cage, use a blunt ended screwdriver to pry the balls from the cage.





13. Align the ball cage windows with the outer race lands, and pivot the ball cage and inner race assembly until it is straight up and down in the outer race.





14. Lift the assembly out of the outer race.





15. Rotate the inner race upward and out of the ball cage.

Assembly
1. Apply a light coat of grease to the inner race, the ball cage, and the outer race.
^ Use Constant Velocity Joint Grease (High Temp) XG-5 or equivalent meeting Ford specification WSS-MlC258-A1.





2. Install the inner race in the ball cage.








3. Install the inner race and ball cage assembly.
1. Install the assembly vertically, and pivot it 90 degreesinto position.
2. The chamfer must face upward when installed in the outer race.





4. Tilt the inner race and ball cage assembly, and install the balls.





5. CAUTION: Do not damage the front brake anti-lock sensor indicator. Tooth damage will affect brake performance.

Position the special tool on a press bed, and place the front brake anti-lock sensor indicator on the special tool.





6. Position the front wheel driveshaft joint in the special tool.





7. Place a steel plate across the front wheel driveshaft joint back face.





8. NOTE: Installation is complete when the front wheel driveshaft joint bottoms out in the special tool.

Press the front brake anti-lock sensor indicator on the front wheel driveshaft joint.





9. NOTE: Make the front wheel driveshaft joint boot seats in the shaft boot groove.

If removed, install the clamp and the front wheel driveshaft joint boot.





10. Install the clamps as tight as possible by hand.





11. Using the special tool, tighten the clamp.
^ Position the special tool on the clamp ear, and tighten the tool through bolt until the tool closes completely.

12. NOTE: Make sure the stop ring seats in the groove.

If removed, install the stop ring.





13. CAUTION: Do not reuse the circlip.

CAUTION: Do not over-expand or twist the circlip during installation.

Install a new circlip.
^ Start one end in the groove and work the circlip over the shaft and into the groove. This will avoid over-expanding the circlip.





14. Fill the front wheel driveshaft joint with 180 grams (6.3 ounces) of grease. Spread the remaining grease evenly inside the front wheel driveshaft joint boot.
^ Use Constant Velocity Joint Grease (High Temp) XG-5 or equivalent meeting Ford specification WSS-MlC258-A1.





15. NOTE: The front wheel driveshaft joint has seated when the circlip locks in the groove cut in the inner race.

Using a non-metallic hammer, tap the front wheel driveshaft joint onto the interconnecting shaft. Make sure the front wheel driveshaft joint has locked on the interconnecting shaft by attempting to pull the joint off of the shaft.





16. NOTE: Remove all excess grease from the front wheel driveshaft joint external surface and the front wheel driveshaft joint boot mating surface.

Seat the front wheel driveshaft joint boot in the front wheel driveshaft joint boot groove.





17. Install the clamp as tight as possible by hand.





18. Using the special tool, tighten the clamp.
^ Position the special tool on the clamp ear, and tighten the tool through bolt until the tool closes completely.