Outer Joint and Boot

Disassembly


The constant velocity joint components are matched during manufacture and cannot be interchanged with components from another constant velocity joint. Extreme care should be taken not to intermix or substitute like components between constant velocity joints.
1. Clamp halfshaft into a suitable vise. Do not allow vise jaws to contact boot or clamp.
2. Cut large boot clamp and peel away from boot.
3. Support interconnecting shaft in a soft jaw vise and angle constant velocity joint to expose inner bearing race.
4. Using a brass drift and hammer, give a sharp tap to the inner bearing race to dislodge the internal snap ring and separate the constant velocity joint from the interconnecting shaft. The boot can now be removed from the shaft.
5. Inspect constant velocity joint grease for contamination. If constant velocity joints are operating satisfactorily, and grease does not appear to be contaminated, add grease and replace boot. If lubricant appears contaminated, proceed with a complete constant velocity joint disassembly and inspection.
6. Remove snap ring located near end of shaft. Discard snap ring. A new snap ring is supplied with both boot replacement kit and constant velocity joint. The stop ring, located just below the snap ring, should only be removed if it is damaged.
7. Clamp the constant velocity joint stub shaft in a vise with outer facing pointing upward. Care should be taken not to damage the dust seal.
8. Press down on inner race until it tilts enough to allow removal of the ball.
9. With cage tilted, remove ball from cage. Repeat until all six balls are removed.
10. Pivot cage and inner race assembly until it is facing straight up and down in outer race. Align cage windows with the outer race lands while pivoting bearing race. With cage pivoted and aligned, lift assembly from outer race.
11. Rotate inner race up and out of cage.

Assembly


Because the constant velocity joint components are matched as a set during assembly, individual components are not available for service. If inspection determines a part to be worn or damaged, the constant velocity joint should be replaced as an assembly. Do not replace a joint because the components appear polished. Shiny areas in ball races and the cage spheres are normal. A constant velocity joint should be replaced only if inspection determines a component to be cracked, broken, severely pitted, worn or otherwise unserviceable.
1. Apply a light coat of grease onto inner and outer ball races. Use only Ford CV grease E2FZ-19590-A or equivalent.
2. Install inner race into bearing cage.
3. Install inner race and cage assembly into outer race.
4. Install assembly vertically and pivot 90° into position.
5. Align bearing cage and inner race with outer race.
6. Tilt inner race and cage, then install a ball. Repeat this step until all six balls are installed.

Fig. 10 Halfshaft End Identification:

7. The lefthand and righthand interconnecting shafts are not the same end-for-end. The outboard end is shorter from end of shaft to end of boot groove than the inboard end. Take a measurement to ensure correct inboard and outboard constant velocity joint to shaft installation, Fig. 2.
8. If removed, install constant velocity joint boot after removing stop ring.
9. Ensure boot is properly seated in its groove and clamp into position.
10. If removed, install stop ring. If not removed, ensure stop ring is properly seated in groove.
11. Install a new snap ring, supplied with service kit, in groove nearest end of shaft.
12. Do not over expand or twist snap ring during installation.
13. Before positioning boot over constant velocity joint, pack constant velocity joint and boot with grease supplied in service kit. Add 3.52 ounces.
14. With boot peeled back, position constant velocity joint on shaft and tap into position. The constant velocity joint is completely seated when the snap ring locks in groove cut into constant velocity joint inner race. Check for snap ring seating by trying to pull joint from shaft.
15. Remove all excess grease from the constant velocity joint external surfaces.
16. Position boot over constant velocity joint.
17. Ensure boot is seated in its groove and clamp in position.