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Axle Shafts: Reassembly

WARNING: This page is about a different car, the 2003 Ford Windstar and 2002 Ford Windstar. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the CV joint boot. See Fig 4 . Position the CV joint boot into the small groove.
  2. Using the Constant Velocity Joint Boot Clamp Installer (205-343, T95P-3514-A), install the small CV joint boot clamp. See Fig 5 . Position the constant velocity joint boot clamp installer on the clamp ear, and tighten the tool through bolt, until the tool closes completely.
  3. Install the axle shaft outer CV joint boot and the CV joint. See REASSEMBLY (OUTER JOINT)  .
    4. CAUTION: The right side axle shaft and the left side axle shaft use different types of grease.
  4. Fill the right side inner CV joint housing with 7.1 oz. (201 grams) of Ford High Temp Constant Velocity Joint Grease (E43Z-19590-A). Spread the remaining grease evenly inside the CV joint boot.
  5. Fill the left side inner CV joint housing with 8.8 oz. (249 grams) of GKN Thermax Grease (M-3020). Spread any remaining grease evenly inside the CV joint boot.
    6. NOTE: Remove all excess grease from the CV joint external surface and the CV joint boot sealing surface.
  6. Seat the CV joint boot in the inner CV joint housing boot groove. See Fig 2 .
  7. Set the axle shaft assembled length to specification. See AXLE SHAFT ASSEMBLED LENGTH  table. Measure the axle shaft assembly length. See Fig 6 . Push in or pull out on the inner joint as necessary to adjust the axle shaft assembled length to specification. Hold the inner joint to prevent the assembled length from changing, and insert a small flat blade screwdriver between the CV joint boot and the CV joint housing to equalize the pressure.
    8. NOTE: Make sure the CV joint boot seats in the groove.
  8. Install the large CV joint boot clamp as tight as possible by hand. See Fig 7 .
  9. Using constant velocity joint boot clamp installer, tighten the large CV joint boot clamp. See Fig 8 . Position the constant velocity joint boot clamp installer on the clamp ear, and tighten the tool through bolt until the tool closes completely.
  10. Move the CV joints through their full range of travel at various angles. The joints must flex, extend and compress smoothly. See Fig 9 .
AXLE SHAFT ASSEMBLED LENGTH

Application Specification In. (mm)
Left Side 24.07 (611.5)
Right Side 29.34 (745.3)
Fig 1: Removing CV Joint Boot Clamps
G00203938Courtesy of FORD MOTOR CO.
Fig 2: Removing & Installing CV Joint Boot (At CV Joint Housing)
G00203939Courtesy of FORD MOTOR CO.
Fig 3: Checking Grease For Contamination
G00203940Courtesy of FORD MOTOR CO.
Fig 4: Removing & Installing CV Joint Boot (At Axle Shaft)
G00203943Courtesy of FORD MOTOR CO.
Fig 5: Tightening Small CV Joint Boot Clamp
G00203944Courtesy of FORD MOTOR CO.
Fig 6: Measuring Axle Shaft Assembly Length
G00203945Courtesy of FORD MOTOR CO.
Fig 7: Installing Large CV Joint Boot Clamp
G00203946Courtesy of FORD MOTOR CO.
Fig 8: Tightening Large CV Joint Boot Clamp
G00203947Courtesy of FORD MOTOR CO.
Fig 9: Checking CV Joint Movement
G00203948Courtesy of FORD MOTOR CO.
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