Disassembly And Assembly: Halfshaft: 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.
Lubricate the outboard CV joint.
1. Pack the outboard CV joint with 185 grams (6.53 oz) of grease.
  - One-third of the grease must be installed in the joint with the remainder placed in the boot.
2. Spread the remaining grease evenly inside the boot.
  
  Fig 2: Spreading Remaining Grease Evenly Inside Boot
  Courtesy of FORD MOTOR CO.
Position the outboard half shaft boot and the outboard boot clamps.
1. Position the boot.
2. Position the boot clamps.
  
  Fig 3: Positioning Boot Clamps
  Courtesy of FORD MOTOR CO.
Install the outboard CV boot clamps.

Fig 4: Installing Outboard CV Boot Clamps
Courtesy of FORD MOTOR CO.
Position the inboard clamp and boot.

Fig 5: Positioning Inboard Clamp And Boot
Courtesy of FORD MOTOR CO.
Install the CV joint and snap ring on the halfshaft.

Fig 6: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Install the stop ring.

Fig 7: Installing Stop Ring
Courtesy of FORD MOTOR CO.
Fill the inboard CV joint housing with 210 grams (7.41 oz) of grease.
- One-half of the grease must be installed in the joint and the remainder placed in the boot.
  
  Fig 8: Identifying Inboard CV Joint Housing
  Courtesy of FORD MOTOR CO.
Position the CV housing on the CV joint.

Fig 9: Identifying Inboard CV Joint & Housing
Courtesy of FORD MOTOR CO.
Position the inboard halfshaft boot and clamp.
1. Position the boot in the housing groove.
2. Position the boot clamp.
  
  Fig 10: Positioning Boot In Housing Groove
  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 11: Setting Halfshaft
  Courtesy of FORD MOTOR CO.
Using the special tool, install the boot clamps.

Fig 12: Installing Boot Clamps
Courtesy of FORD MOTOR CO.
Install the halfshaft assembly. For additional information, refer to HALFSHAFT .