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Axle Shafts: Reassembly

WARNING: This page is about a different car, the 2002 Mercury Villager. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: The inboard and outboard CV joint boots are different. Failure to correctly install the CV joint boot on the correct axle shaft CV joint could lead to premature CV joint boot and CV joint wear.
  1. Place the small CV joint boot clamp over the axle shaft. Place the large CV joint boot clamp over the axle shaft CV joint housing.
  2. Slide the CV joint boot onto the axle shaft and remove the tape from the splines.
  3. Using the recorded measurement, install the dynamic dampner. See Figure .
  4. Install NEW dynamic dampner clamps, using Boot Clamp Pliers (205-D067, D87P-1O98-A), to pull the CV joint boot clamps tight and bend the locking tabs to secure the CV joint boot clamps.
  5. Position the "C" clip on the axle shaft past the recess.
    6. NOTE: Position the inner race so the smaller bore slides on the shaft first.
  6. Place the inner race past the "C" clip recess. Install the circlip. See Figure .
  7. Install the "C" clip. Slide the inner race forward over the circlip. Install the "C" clip. See Figure .
  8. Install the bearing cage. See Figure . Lubricate the inboard and outboard axle shaft CV joint bearings with High Temperature Constant Velocity Joint Grease (E43Z-19590-A).
    9. CAUTION: DO NOT drop ball bearings, damage may result.
  9. Connect the inner race and outer race. See Figure . Carefully position the ball bearings in the CV joint bearing cage. Place the inner race assembly in the outer race.
  10. Install the wire ring bearing retainer on the axle shaft joint. See Figure .
  11. Position the CV joint boot and clamps over the joint.
    12. CAUTION: Tighten the CV joint boots securely, but not to the point where the CV joint boot clamp bridge is cut or damage may result.
  12. Using the boot clamp pliers, crimp the CV joint boot clamps as necessary.
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