LEMON Manuals: Even more car manuals for everyone
Home >> Lincoln >> 2005 >> Navigator RWD >> Repair and Diagnosis >> Drivelines & Axles >> Axle Shafts >> Front Drive HALFSHAFTS >> Disassembly And Assembly >> Halfshaft >> Assembly

Disassembly And Assembly: Halfshaft: Assembly

  1. Position the outboard boot on the shaft.
    Fig 1: Positioning Outboard Boot On Shaft
    G03961251Courtesy 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
      G03928584Courtesy 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 Boot
      G03928585Courtesy 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 Shaft Groove
    G03928586Courtesy of FORD MOTOR CO.
  5. Position the boot clamps.
    Fig 5: Positioning Boot Clamps
    G03961250Courtesy of FORD MOTOR CO.
    6. NOTE: Tighten the through-bolt until the tool is in the CLOSED position.
    Fig 6: Installing Boot Clamps
    G03928588Courtesy 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 Boot Clamp On Shaft
    G03961257Courtesy of FORD MOTOR CO.
  8. Position the inboard boot on the shaft.
    Fig 8: Positioning Inboard Boot On Shaft
    G03928590Courtesy of FORD MOTOR CO.
  9. Position the ball cage on the shaft with the tapered end facing the boot.
    Fig 9: Positioning Ball Cage On Shaft With Tapered End Facing Boot
    G03928591Courtesy of FORD MOTOR CO.
  10. Position the inner race on the shaft with the counterbored end facing the boot.
    NOTE: Align the index marks.
    Fig 10: Positioning Inner Race On Shaft
    G03961260Courtesy of FORD MOTOR CO.
  11. Install the snap ring.
    Fig 11: Installing Snap Ring
    G03961247Courtesy 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: Positioning Balls
      G03928594Courtesy 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
      G03961263Courtesy 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 Shaft Groove
    G03928586Courtesy of FORD MOTOR CO.
  15. Position the boot clamp on the inboard CV joint housing.
    Fig 15: Positioning Boot Clamp On Inboard CV Joint Housing
    G03961264Courtesy of FORD MOTOR CO.
  16. Position the inboard CV joint housing on the ball and race assembly.
    Fig 16: Positioning Inboard CV Joint Housing On Ball And Race Assembly
    G03961265Courtesy of FORD MOTOR CO.
  17. Install the retaining ring.
    Fig 17: Installing Retaining Ring
    G03961266Courtesy of FORD MOTOR CO.
  18. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove.
    Fig 18: Seating Boot In Joint Boot Groove
    G03961242Courtesy of FORD MOTOR CO.
  19. Set the halfshaft assembled length to specification. For additional information, refer to SPECIFICATIONS .
    Fig 19: Identifying Halfshaft Assembled Length
    G03928601Courtesy of FORD MOTOR CO.
    20. CAUTION: Do not damage the boot.
    Fig 20: Inserting Dull Screwdriver Blade Under Boot For Releasing Pressure
    G03961269Courtesy 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 Boot Clamps
    G03928603Courtesy of FORD MOTOR CO.
  21. Using the special tool, install the 2 boot clamps.
    22. NOTE: Maintain a clean work surface.
    Fig 22: Compressing Integrated Wheel End Disconnect On Bench
    G03928604Courtesy 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: Installing Vacuum Cap On Vacuum Port
    G03928605Courtesy 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: Installing Integrated Wheel End Disconnect On Outer Constant Velocity Joint Housing
    G03928606Courtesy 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 .
scientia non olet · About LEMON Manuals