Ford Overhaul FRONT SHAFT & REAR HALFSHAFT?

The details are for Clutch system Drive train  CV-Joints Overhaul for Front shaft and Rear half shaft.


Overhaul
FRONT SHAFT
REAR HALFSHAFT

Procedure will work for
Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005.


The instructions are as follows :---

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Halfshaft and place it in a vice with the inboard joint lower than the outboard joint
3. Cut the inner boot clamps with side cutters and remove the clamp from the boot.
   
   NOTE

   The outboard CV-joint is non-serviceable other than to replace the boot.
   
   
   
   
   Larger boot end off the joint

   Inboard CV-joint bolts and separate the spacer and grease cap

   Snap-ring retaining the interconnecting shaft end to the CV-joint cage

   CV-joint and discard the washer

To install:

1. Install or connect the following:
   
   
   Slide the boot over the shaft
2. Fill the CV-joint area with grease.
   
   
   Assemble the outer boot to the outboard CV-joint and interconnecting shaft. Make certain that the boot is seated in the grooves on the outer race and on the shaft

   New clamps to the boot

   New inner boot to the shaft

   New washer to the end of the shaft

   Assemble the inboard CV-joint to the interconnecting shaft spline until it rests on the washer

   Snap-ring
3. Fill the CV-joint area with grease.
   
   
   Boot into position and make certain that it is seated in the grooves on the boot adapter and the shaft

   New clamps and tighten the clamps with crimping pliers

   Spacer to the CV-joint end pilot. Torque the bolts to 25 ft. lbs. (34 Nm).

   Halfshaft

   Negative battery cable

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Remove or disconnect the following:
   
   
   Halfshaft

   The two inboard boot clamps

   Inboard halfshaft boot off the inboard CV-joint housing
3. Separate the CV-joint from the CV-joint housing.
4. Mark the shaft and the inboard CV-joint to ease alignment during assembly.
5. Remove the snap ring.
6. Remove the CV-joint.
7. Inspect the stop ring for wear or damage. Install a new stop ring as necessary.
8. Remove the inboard halfshaft boot from the shaft assembly.
9. Remove the two outboard boot clamps.
10. Remove the outboard halfshaft boot.
    
    NOTE

    If grease is contaminated, clean and inspect the joint for wear. If worn or damaged, install a new outboard CV-joint and shaft assembly.
    
    
    
    
    

    

    Fig. Remove the stop ring-2002-04 front shaft
    
    
    
    

    

    Fig. Remove the snap ring-2002-04 front shaft
    
    
    
    

    

    Fig. Remove the joint-2002-04 front shaft
    
    
    
    

    

    Fig. Crimping the boot clamps-2002-04 front shaft

To assemble

1. Pack the outboard CV-joint with grease.
   
   NOTE

   Clean the halfshaft boot mounting surfaces of access grease before positioning the halfshaft boot into place.
2. Position the outboard halfshaft boot and outboard boot clamps.
3. Tighten the through-bolt until the installer is in the closed position.
4. Use the CV Boot Clamp Installer to install the outboard CV-joint boot clamps.
5. Position the boot clamp on the halfshaft.
6. Position the inboard halfshaft boot.
7. Install a new stop ring, if necessary.
8. Install the CV-joint on the halfshaft.
9. Install the snap-ring.
10. Lubricate the three CV-joint needle bearings with grease.
11. Fill the inboard CV-joint housing with 235 grams of grease.
12. Position the CV-joint housing onto the CV-joint.
    
    NOTE

    Remove any excess grease from the inboard halfshaft boot mating surface before positioning into place.
13. Position the inboard halfshaft boot and boot clamp.
14. Set the halfshaft assembled length to:
    
    
    Aviator, Explorer, Mountaineer: 24.22 inches (615.3mm) for the right side; 26.98 inches (685.3mm) for the left.

    Explorer Sport-Trac: 24.72 inches (618mm) for the left side; 21.92 inches (548mm) for the right side
15. Measure the entire assembly length. Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length. 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.
16. Insert a wood wand to relieve built-up air pressure in the halfshaft boot.
17. Use the CV Boot Clamp Installer to install the inboard boot clamps.
18. Install the front wheel halfshaft.

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Remove or disconnect the following:
3. Remove the halfshaft.
4. For the inboard CV-joint:
   1. Remove and discard the boot clamps.
   2. Remove the inboard CV-joint housing.
   3. Remove and discard the retainer circlip.
   4. Slide the boot away from the CV-joint.
   5. Using a suitable 3-jaw puller, remove the CV-joint.
   6. Remove and discard the tri-lobe insert and the boot.
5. For the outboard CV-joint:
   1. Remove and discard the boot clamps.
   2. Remove and discard the boot.
      
      NOTE

      Do not disassemble the side shaft assembly. Install a new halfshaft assembly, if the components are worn/damaged.
6. Inspect the grease packed in the inboard CV-joint and the outboard CV-joint for contamination. Rub some of the grease from each joint between two fingers. Any gritty feeling indicates contamination. Wash all of the grease from the inboard CV-joint, the inboard CV-joint housing, the outboard CV-joint, and the interconnecting shaft. Thoroughly dry all of the components, and inspect them for wear and damage. Discard the assembly, if necessary. Proceed as follows only if not discarding the assembly.
7. If necessary, remove and discard the outboard dust seal. Tap uniformly around the seal to separate it from the joint.
8. On the inboard end:
   1. Remove and discard the retainer circlip.
   2. If necessary, remove and discard the inboard dust seal. Tap uniformly around the seal to separate it from the housing.

To assemble:

1. For the outboard CV-joint:
   1. Slide the boot on the interconnecting shaft.
   2. Pack the outboard CV-joint with 5.29 ounces (225 grams) of grease.
   3. Spread any remaining grease evenly inside the boot.
   4. Clean any excess grease from the boot mounting surfaces before installing the boot.
   5. Install the boot by seating it in the groove in the CV-joint housing.
   6. Tighten the through-bolt until the special tool is in the closed position.
   7. Using the special tool, install both boot clamps.
   8. If removed, use the special tools to install the dust seal.
      
      WARNING

      Do not over-expand or twist the circlip during installation.
   9. Install the retainer circlip.
2. Install the halfshaft in a soft jaw vise.
3. For the inboard CV-joint:
   1. Position the clamp on the interconnecting shaft.
   2. Position the boot on the interconnecting shaft.
      
      NOTE

      The lip on the end of the tri-lobe insert must seat against the end of the boot.
   3. Install the tri-lobe insert.
      
      NOTE

      One side of the inboard CV-joint has a chamfer cut in the edge of joint at the inner diameter near the splines. Install the inboard CV-joint so that the chamfer faces the outboard end of the halfshaft.
   4. Install the CV-joint.
   5. Install the retainer circlip.
   6. Pack the inboard CV-joint housing with 7.93 ounces (225 grams) of grease.
   7. Spread any remaining grease evenly inside the boot and on the CV-joint.
   8. Clean any excess grease from the boot mounting surfaces before installing the boot.
   9. Install the inboard CV-joint housing, seating the boot in the groove in the housing.
4. Set the halfshaft assembled length to:
   
   
   2002-03 Explorer and Mountaineer: 28.44 inches (722.4 mm)

   Aviator and 2004-05 Explorer and Mountaineer: right side 33.94 inches (862.1 mm); left side 32.82 inches (833.7mm)
5. Hold the inner joint to prevent the assembled length from changing, and insert a wood wand between the boot and the joint to equalize the pressure.
6. Tighten the through-bolt until the special tool is in the closed position.
7. Install both boot clamps.
8. If removed, install the dust seal.
9. Install the halfshaft.

Front Shaft

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   
   Halfshaft

   The two inboard boot clamps

   Inboard halfshaft boot off the inboard CV joint housing
3. Separate the CV joint from the CV joint housing.
4. Mark the shaft and the inboard CV joint to ease alignment during assembly.
5. Remove the snap ring.
6. Remove the CV joint.
7. Inspect the stop ring for wear or damage. Install a new stop ring as necessary.
8. Remove the inboard halfshaft boot from the shaft assembly.
9. Remove the two outboard boot clamps.
10. Remove the outboard halfshaft boot.
    
    NOTE

    If grease is contaminated, clean and inspect the joint for wear. If worn or damaged, install a new outboard CV joint and shaft assembly.

To assemble

1. Pack the outboard CV joint with grease.
   
   NOTE

   Clean the halfshaft boot mounting surfaces of access grease before positioning the halfshaft boot into place.
2. Position the outboard halfshaft boot and outboard boot clamps.
3. Tighten the through-bolt until the installer is in the closed position.
4. Use the CV Boot Clamp Installer to install the outboard CV joint boot clamps.
5. Position the boot clamp on the halfshaft.
6. Position the inboard halfshaft boot.
7. Install a new stop ring, if necessary.
8. Install the CV joint on the halfshaft.
9. Install the snap-ring.
10. Lubricate the three CV joint needle bearings with grease.
11. Fill the inboard CV joint housing with 235 grams of grease.
12. Position the CV joint housing onto the CV joint.
    
    NOTE

    Remove any excess grease from the inboard halfshaft boot mating surface before positioning into place.
13. Position the inboard halfshaft boot and boot clamp.
14. Insert a wood wand to relieve built-up air pressure in the halfshaft boot.
15. Use the CV Boot Clamp Installer to install the inboard boot clamps.
16. Install the front wheel halfshaft.

Rear Halfshaft

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
3. Remove the halfshaft.
4. For the inboard CV joint:
   1. Remove and discard the boot clamps.
   2. Remove the inboard CV joint housing.
   3. Remove and discard the retainer circlip.
   4. Slide the boot away from the CV joint.
   5. Using a suitable 3-jaw puller, remove the CV joint.
   6. Remove and discard the tri-lobe insert and the boot.
5. For the outboard CV joint:
   1. Remove and discard the boot clamps.
   2. Remove and discard the boot.
      
      NOTE

      Do not disassemble the side shaft assembly. Install a new halfshaft assembly, if the components are worn/damaged.
6. Inspect the grease packed in the inboard CV joint and the outboard CV joint for contamination. Rub some of the grease from each joint between two fingers. Any gritty feeling indicates contamination. Wash all of the grease from the inboard CV joint, the inboard CV joint housing, the outboard CV joint, and the interconnecting shaft. Thoroughly dry all of the components, and inspect them for wear and damage. Discard the assembly, if necessary. Proceed as follows only if not discarding the assembly.
7. If necessary, remove and discard the outboard dust seal. Tap uniformly around the seal to separate it from the joint.
8. On the inboard end:
   1. Remove and discard the retainer circlip.
   2. If necessary, remove and discard the inboard dust seal. Tap uniformly around the seal to separate it from the housing.

To assemble:

1. For the outboard CV joint:
   1. Slide the boot on the interconnecting shaft.
   2. Pack the outboard CV joint with 225 grams (5.29 ounces) of grease.
   3. Spread any remaining grease evenly inside the boot.
   4. Clean any excess grease from the boot mounting surfaces before installing the boot.
   5. Install the boot by seating it in the groove in the CV joint housing.
   6. Tighten the through-bolt until the special tool is in the closed position.
   7. Using the special tool, install both boot clamps.
   8. If removed, use the special tools to install the dust seal.
      
      WARNING

      Do not over-expand or twist the circlip during installation.
   9. Install the retainer circlip.
2. Install the halfshaft in a soft jaw vise.
3. For the inboard CV joint:
   1. Position the clamp on the interconnecting shaft.
   2. Position the boot on the interconnecting shaft.
      
      NOTE

      The lip on the end of the tri-lobe insert must seat against the end of the boot.
   3. Install the tri-lobe insert.
      
      NOTE

      One side of the inboard CV joint has a chamfer cut in the edge of joint at the inner diameter near the splines. Install the inboard CV joint so that the chamfer faces the outboard end of the halfshaft.
   4. Install the CV joint.
   5. Install the retainer circlip.
   6. Pack the inboard CV joint housing with 250 grams (5.88 ounces) of grease.
   7. Spread any remaining grease evenly inside the boot and on the CV joint.
   8. Clean any excess grease from the boot mounting surfaces before installing the boot.
   9. Install the inboard CV joint housing, seating the boot in the groove in the housing.
4. Set the halfshaft assembled length to 28.44 inches (722.4mm).
5. Hold the inner joint to prevent the assembled length from changing, and insert a wood wand between the boot and the joint to equalize the pressure.
6. Tighten the through-bolt until the special tool is in the closed position.
7. Install both boot clamps.
8. If removed, install the dust seal.
9. Install the halfshaft.

This details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html