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Axle Shafts: Reassembly

WARNING: This page is about a different car, the 2004 Ford Ranger, 2003 Ford Ranger, and 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: For axle shaft assembled length, see AXLE SHAFT ASSEMBLED LENGTH  table.
  1. If you are not replacing the outer CV joint boot, go to step  4 . If you are replacing outer CV joint boot, position the outboard boot on the shaft. Pack the outboard CV joint with 5.82 ounces (165 grams) of grease. Use High Temp Constant Velocity Joint Grease (E43Z-19590-A), or equivalent provided in the boot kit.
  2. Spread any remaining grease from the kit evenly inside the boot. Clean the boot mounting surface. See Fig 9 . Seat the boot in the joint boot groove. Position the boot clamps.
    3. NOTE: Tighten the through-bolt until the tool is in the closed position.
  3. Using CV Boot Clamp (205-343, T95P-3514-A), install the two boot clamps. See Fig 10 .
  4. Position the inner boot clamp on the shaft. Position the inner boot on the shaft.
  5. Align the index marks on the axle shaft and the CV joint. See Fig 4 . Install the CV joint on the axle shaft. Install the snap ring. See Fig 5 .
  6. Lubricate the three CV joint needle bearings. See Fig 11 . Use Ford High Temp Constant Velocity Joint Grease (E43Z-19590-A), or equivalent.
  7. Fill the inner CV joint housing with 235 grams of grease. Use Ford High Temp Constant Velocity Joint Grease (E43Z-19590-A), or equivalent.
  8. Position the CV joint housing onto the CV joint. See Fig 3 . Remove any excess grease from the inner axle shaft boot mating surface before positioning it into place. Position the inner axle shaft boot and boot clamp. Position the inner axle shaft boot into place. Position the boot clamp.
  9. Seat the boot in the joint boot groove. Insert a dulled screwdriver blade to relieve built-up air pressure in the axle shaft boot. See Fig 12 .
    10. NOTE: Tighten the through-bolt until the tool is in the closed position.
  10. Using CV Boot Clamp (205-343, T95P-3514-A), install the two boot clamps. See Fig 13 . Using Parking Break Bearing Installer (206-040, T88T-2598-F) , install the new front wheel excluder seal, if removed. See Fig 14 . Seat the metal ring at the seal's inner diameter flat against the CV joint housing.
  11. Install the axle shaft in the vehicle. See AXLE SHAFTS  under REMOVAL & INSTALLATION.
AXLE SHAFT ASSEMBLED LENGTH

Application In. (mm)
Left & Right Side 16.43 (417.3)
Fig 1: Locating Inner CV Joint Boot Clamps
G00307426Courtesy of FORD MOTOR CO.
Fig 2: Separating Boot From CV Joint Housing
G00307427Courtesy of FORD MOTOR CO.
Fig 3: Removing/Installing CV Joint At CV Housing
G00307428Courtesy of FORD MOTOR CO.
Fig 4: Index-Marking Shaft & Inner CV Joint
G00307429Courtesy of FORD MOTOR CO.
Fig 5: Locating Snap Ring
G00307430Courtesy of FORD MOTOR CO.
Fig 6: Removing Inner CV Joint From Axle Shaft
G00307431Courtesy of FORD MOTOR CO.
Fig 7: Removing Front Wheel Excluder Seal
G00307432Courtesy of FORD MOTOR CO.
Fig 8: Checking Grease For Contamination
G00203940Courtesy of FORD MOTOR CO.
Fig 9: Installing Outer CV Joint Boot
G00307391Courtesy of FORD MOTOR CO.
Fig 10: Installing Outer CV Joint Boot Clamps
G00307392Courtesy of FORD MOTOR CO.
Fig 11: Lubricating The 3 CV Joint Needle Bearings
G00307433Courtesy of FORD MOTOR CO.
Fig 12: Relieving Air Pressure In CV Boot
G00307434Courtesy of FORD MOTOR CO.
Fig 13: Installing Inner Boot Clamps
G00307435Courtesy of FORD MOTOR CO.
Fig 14: Installing Front Wheel Excluder Ring Seal
G00307436Courtesy of FORD MOTOR CO.
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