Outer Joint and Boot

REMOVAL

NOTE: The CV joint components are matched during manufacturing and cannot be interchanged with components from another joint. Do not intermix or substitute components between joints.

1. Clamp driveshaft into a 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 CV 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 CV joint from the interconnecting shaft. The boot can now be removed from the shaft.
5. Inspect CV joint grease for contamination. If CV joints are operating satisfactorily, and grease does not appear to be contaminated, add grease and replace boot. If grease appears contaminated or has a gritty feeling, inspect for worn components and replace as necessary.
6. Remove snap ring located near end of shaft. Discard snap ring. A new snap ring is supplied with both boot replacement kit and CV joint. The stop ring, located just below the snap ring, should only be removed if it is damaged.
7. Clamp the CV 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.

INSTALLATION

NOTE: Because the CV 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 CV joint should be replaced as an assembly. Do not replace a joint if the components appear polished. Shiny areas in ball races and the cage spheres are normal. A CV 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 its 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. 2 Interconnecting Shaft 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 proper inboard and outboard CV joint to shaft installation.
8. If removed, install CV 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 overexpand or twist snap ring during installation.
13. Before positioning boot over CV joint, pack CV joint and boot with grease supplied in service kit. Add 3.52 ounces.
14. With boot peeled back, position CV joint on shaft and tap into position.

NOTE: The CV joint is completely seated when the snap ring locks in groove cut into CV joint inner race. Inspect for snap ring seating by trying to pull joint from shaft.

15. Remove all excess grease from the CV joint external surfaces.
16. Position boot over CV joint.
17. Ensure boot is seated in its groove and clamp in position.