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Disassembly And Assembly: Halfshaft: Assembly

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  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. Pack the outboard CV joint with grease.
    2. Spread any remaining grease from the kit evenly inside the boot.
    Fig 2: Packing Outboard CV Joint With 165 Grams (5.82 Ounces) Of Grease
    G03961253Courtesy of FORD MOTOR CO.
  3. Install the outboard boot.
    1. Clean the boot mounting surface.
    2. Seat the boot in the CV joint boot groove.
    Fig 3: Installing Outboard Boot
    G03961254Courtesy of FORD MOTOR CO.
  4. Position the boot clamps.
    Fig 4: Positioning Boot Clamps
    G03961250Courtesy of FORD MOTOR CO.
    5. NOTE: Tighten the through-bolt until the tool is in the closed position.
    Fig 5: Using Special Tool To Install 2 Boot Clamps
    G03961256Courtesy of FORD MOTOR CO.
  5. Using the special tool, install the 2 boot clamps.
  6. Position the boot clamp on the shaft.
    Fig 6: Positioning Boot Clamp On Shaft
    G03961257Courtesy of FORD MOTOR CO.
  7. Position the inboard boot on the shaft.
    Fig 7: Positioning Inboard Boot On Shaft
    G03928590Courtesy of FORD MOTOR CO.
  8. Position the ball cage on the shaft with the tapered end facing the boot.
    Fig 8: Positioning Ball Cage On Shaft With Tapered End Facing Boot
    G03961259Courtesy of FORD MOTOR CO.
    9. NOTE: Align the index marks.
    Fig 9: Positioning Inner Race On Shaft With Counterbored End Facing Boot
    G03961260Courtesy of FORD MOTOR CO.
  9. Position the inner race on the shaft with the counterbored end facing the boot.
  10. Install the snap ring.
    Fig 10: Installing Snap Ring
    G03961247Courtesy of FORD MOTOR CO.
  11. Lubricate and position the 6 balls with grease.
    Fig 11: Lubricating And Positioning 6 Balls With Grease
    G03928594Courtesy of FORD MOTOR CO.
  12. Fill the inboard CV joint housing with 235 grams (8.29 ounces) of grease.
    Fig 12: Filling Inboard CV Joint Housing With 235 Grams (8.29 Ounces) Of Grease
    G03961263Courtesy of FORD MOTOR CO.
  13. Position the boot clamp on the inboard CV joint housing.
    Fig 13: Positioning Boot Clamp On Inboard CV Joint Housing
    G03961264Courtesy of FORD MOTOR CO.
  14. Position the inboard CV joint housing on the ball and race assembly.
    Fig 14: Positioning Inboard CV Joint Housing On Ball And Race Assembly
    G03961265Courtesy of FORD MOTOR CO.
  15. Install the retaining ring.
    Fig 15: Installing Retaining Ring
    G03961266Courtesy of FORD MOTOR CO.
  16. Remove any excess grease from the mating surface. Seat the boot in the CV joint boot groove.
    Fig 16: Removing Any Excess Grease From Mating Surface
    G03961242Courtesy of FORD MOTOR CO.
  17. Set the halfshaft assembled length to specification. For additional information, refer to SPECIFICATIONS .
    Fig 17: Setting Halfshaft Assembled Length Specification
    G03961268Courtesy of FORD MOTOR CO.
    18. CAUTION: Do not damage the boot.
    Fig 18: Inserting Dull Screwdriver Blade Under Boot To Release Pressure
    G03961269Courtesy of FORD MOTOR CO.
  18. Insert a dull screwdriver blade under the boot to release the pressure.
    19. NOTE: Tighten the through-bolt until the tool is in the closed position.
    Fig 19: Using Special Tool To Install 2 Boot Clamps
    G03961270Courtesy of FORD MOTOR CO.
  19. Using the special tool, install the 2 boot clamps.
  20. Install the halfshaft. For additional information, refer to HALFSHAFT .
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