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Disassembly And Assembly: Halfshaft: Assembly

  1. Position the outboard boot on the shaft.
    Fig 1: Identifying Outboard CV Joint Boot
    G04626492Courtesy of FORD MOTOR CO.
  2. Pack the outboard CV joint with 165 grams (5.82 ounces) of grease.
    1. Use constant velocity joint grease or equivalent provided in the boot kit.
    2. Spread any remaining grease from the kit evenly inside the boot.
      Fig 2: Identifying Outboard CV Joint And Boot
      G04626493Courtesy of FORD MOTOR CO.
  3. Install the outboard boot.
    1. Clean the boot mounting surface.
    2. Seat the boot in the joint boot groove.
      Fig 3: Installing Outboard CV Joint Boot
      G04626494Courtesy of FORD MOTOR CO.
  4. Make sure a shaft groove is exposed by positioning the small end of the boot in the groove closest to the constant velocity joint housing.
    Fig 4: Identifying Outboard CV Joint Shaft Groove
    G04626495Courtesy of FORD MOTOR CO.
  5. Position the boot clamps.
    Fig 5: Identifying Outboard CV Joint Boot Clamps
    G04626496Courtesy of FORD MOTOR CO.
    6. NOTE: Tighten the through-bolt until the tool is in the CLOSED position.
    Fig 6: Installing CV Joint Boot Clamps Using Special Tool
    G04626497Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the 2 boot clamps.
  7. Position the boot clamp on the shaft.
    Fig 7: Positioning Inboard Boot Clamp
    G04626498Courtesy of FORD MOTOR CO.
  8. Position the inboard boot on the shaft.
    Fig 8: Identifying Inboard CV Joint Boot
    G04626499Courtesy of FORD MOTOR CO.
  9. Position the ball cage on the shaft with the tapered end facing the boot.
    Fig 9: Identifying Tapered End Of Inboard CV Joint Ball Cage
    G04626500Courtesy of FORD MOTOR CO.
    10. NOTE: Align the index marks.
    Fig 10: Aligning Index Marks
    G04626501Courtesy of FORD MOTOR CO.
  10. Position the inner race on the shaft with the counterbored end facing the boot.
  11. Install the snap ring.
    Fig 11: Identifying Inboard CV Joint Snap Ring
    G04626502Courtesy of FORD MOTOR CO.
  12. Lubricate and position the 6 balls.
    • Use constant velocity joint grease or equivalent provided in the boot kit.
      Fig 12: Identifying Inboard CV Joint Balls
      G04626503Courtesy of FORD MOTOR CO.
  13. Fill the inboard CV joint housing with 235 grams (8.29 ounces) of grease.
    • Use constant velocity joint grease or equivalent provided in the boot kit.
      Fig 13: Identifying Inboard CV Joint Housing
      G04626504Courtesy of FORD MOTOR CO.
  14. Make sure a shaft groove is exposed by positioning the small end of the boot in the groove closest to the constant velocity joint housing.
    Fig 14: Identifying CV Joint Shaft Groove
    G04626505Courtesy of FORD MOTOR CO.
  15. Position the boot clamp on the inboard CV joint housing.
    Fig 15: Positioning CV Joint Boot Clamp
    G04626506Courtesy of FORD MOTOR CO.
  16. Position the inboard CV joint housing on the ball and race assembly.
    Fig 16: Positioning CV Joint Housing On Ball
    G04626507Courtesy of FORD MOTOR CO.
  17. Install the retaining ring.
    Fig 17: Identifying CV Joint Retaining Ring
    G04626508Courtesy of FORD MOTOR CO.
  18. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove.
    Fig 18: Identifying CV Joint Boot
    G04626509Courtesy of FORD MOTOR CO.
  19. Set the halfshaft assembled length to specification. For additional information, refer to SPECIFICATIONS .
    Fig 19: Measuring Halfshaft Assembled Length
    G04626510Courtesy of FORD MOTOR CO.
    20. CAUTION: Do not damage the boot.
    Fig 20: Inserting Dull Screwdriver Blade Under Boot
    G04626511Courtesy of FORD MOTOR CO.
  20. Insert a dull screwdriver blade under the boot to release the pressure.
    21. NOTE: Tighten the through-bolt until the tool is in the closed position.
    Fig 21: Installing CV Joint Boot Clamps Using Special Tool
    G04626512Courtesy of FORD MOTOR CO.
  21. Using the special tool, install the 2 boot clamps.
    22. NOTE: Maintain a clean work surface.
    Fig 22: Compressing IWE Disconnect Vacuum Chamber
    G04626513Courtesy of FORD MOTOR CO.
  22. Compress the integrated wheel end disconnect on the bench to collapse the vacuum chamber.
  23. While the integrated wheel end disconnect is collapsed, install a vacuum cap on the vacuum port.
    Fig 23: Plugging Vacuum Port
    G04626514Courtesy of FORD MOTOR CO.
    24. CAUTION: Do not install the integrated wheel end disconnect in the knuckle. It must be installed on the outer constant velocity joint housing.
    Fig 24: Identifying Outer Constant Velocity Joint Housing
    G04626515Courtesy of FORD MOTOR CO.
  24. Install the integrated wheel end disconnect on the outer constant velocity joint housing.
    25. CAUTION: Verify the spline engagement by checking for spline lash before installing the halfshaft nut.
  25. Install the halfshaft in the vehicle. For additional information, refer to HALFSHAFT  under REMOVAL AND INSTALLATION.
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