Removal and Installation

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Always disconnect the front driveshaft from the transfer case first. Carefully pull the driveshaft out of the CV joint housing. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can, and cause the boot to tear.

CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off of the spider.

NOTE: The front driveshaft CV joint is not repairable.

With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to JACKING & LIFTING .
Index-mark the front axle pinion flange and the front driveshaft.

Fig 1: Identifying Index-Mark Front Axle Pinion Flange And Front Driveshaft
Courtesy of FORD MOTOR CO.
Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.

Fig 2: Identifying Index-Mark Front Output Shaft Assembly
Courtesy of FORD MOTOR CO.

Remove the parts in the order indicated in the following illustration and table.

To remove individual parts, only carry out the listed steps:

PART

Part	Steps
Driveshaft	1-5
Front U-Joint	1-7

Fig 3: Removing Driveshaft Components

Courtesy of FORD MOTOR CO.

To install, reverse the removal procedure.

Item 7: U-Joint Spider Removal Note

Position the driveshaft in the special tool. Using the special tool, press out the bearing cup.

Fig 4: Pressing Out Bearing Cup Using Special Tool
Courtesy of FORD MOTOR CO.
If necessary, use a pair of pliers to remove the bearing cup if it cannot be pressed all the way out.
Rotate the driveshaft and press on the spider to remove the remaining bearing cup.

Item 6: U-Joint Snap Ring Installation Note

Use the yellow snap rings supplied in the kit to install the U-joint. If difficulty is encountered with the yellow snap rings, install the black snap rings, as required.

Item 4: U-Joint Strap Installation Note

Verify that the U -joint bearing caps are seated in the pinion yoke flange before tightening the strap bolts.

Item 3: U-Joint Bolt Installation Note

NOTE: Install new U -joint bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.

Install the new U -joint bolts.

Item 2: CV Joint Installation Note

CAUTION: The can (domed CV joint housing cover) is pressed into the CV joint housing at the factory. When housed correctly, the can will appear as shown in the cut-away illustration (top box). Do not reseat the can in the CV joint housing if the can's flange is above the CV joint housing as shown in the cut-away illustration (bottom box). Install a new driveshaft.

Verify that the can flange is housed correctly in the CV joint housing as shown in the cut-away illustration (top box). Install a new driveshaft if the can flange is not housed correctly.

Fig 5: Locating CV Joint Housing Cover

Courtesy of FORD MOTOR CO.

Item 1: CV Joint Bolts Installation Note

CAUTION: Tighten the bolts evenly in a cross pattern in the sequence shown, or damage will occur to the CV joint.

NOTE: Install new washers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.

Fig 6: Tightening Bolts

Courtesy of FORD MOTOR CO.

Install the new washers and bolts. Tighten the bolts evenly in a cross pattern as shown.