Halfshaft Joint: Assembly

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

If removed, install a new anti-lock brake sensor indicator ring on the outer CV joint.

Fig 1: Installing Anti-Lock Brake Sensor Indicator Ring On Outer CV Joint
Courtesy of FORD MOTOR CO.
For the outboard CV joint, carry out the following:
1. Slide the boot on the interconnecting shaft.
2. Pack the outboard CV joint with 225 grams (7.93 oz.) of grease.
3. Spread any remaining grease evenly inside the boot.
4. Install the boot by seating it in the groove in the CV joint housing.
  
  Fig 2: Installing Boot In CV Joint Housing
  Courtesy of FORD MOTOR CO.
Using the special tool, install the boot clamps.

Fig 3: Installing Boot Clamps
Courtesy of FORD MOTOR CO.

CAUTION: Install a new circlip every time the halfshaft is removed from the axle.

CAUTION: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from overexpanding.

Fig 4: Installing Retainer Circlip

Courtesy of FORD MOTOR CO.

Install a new retainer circlip.
For the inboard CV joint, carry out the following:
1. Position the clamp on the interconnecting shaft.
2. Position the boot on the interconnecting shaft.
3. Install the tri-lobe insert.
  
  Fig 5: Installing Tri-Lobe Insert
  Courtesy of FORD MOTOR CO.
Using the special tool, install the CV joint.

Fig 6: Installing CV Joint
Courtesy of FORD MOTOR CO.
Install the retainer circlip.

Fig 7: Installing Retainer Circlip
Courtesy of FORD MOTOR CO.
For the inboard CV joint, carry out the following:
1. Pack the inboard CV joint housing with 250 grams (8.82 oz.) of grease.
2. Spread any remaining grease evenly inside the boot and CV joint.
3. Install the inboard CV joint housing, seating the boot in the groove in the housing.
  
  Fig 8: Installing Inboard CV Joint Housing
  Courtesy of FORD MOTOR CO.
Set the halfshaft assembled length to specifications. For additional information, refer to SPECIFICATIONS .
1. Measure the entire assembly length.
2. Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length.
3. Hold the inner joint to prevent the assembled length from changing, and insert a small flat-blade screwdriver between the boot and the joint to equalize the pressure.
  
  Fig 9: Adjusting Halfshaft Assembled Length
  Courtesy of FORD MOTOR CO.
Using the special tool, install both boot clamps.

Fig 10: Installing Both Boot Clamps
Courtesy of FORD MOTOR CO.
Install the halfshaft assembly. For additional information, refer to HALFSHAFT .