Aerostar AWD V6-183 3.0L (1991)
Constant Velocity Joint: Service and Repair
Disassembly
Inboard Universal Joint
1. Clamp the halfshaft in a vise. Do not allow vise jaws to contact the halfshaft flange.
2. Remove the snap rings that retain the bearing cups.
3. Position U-joint Tool on the end yoke and PRESS out the bearing. If the bearing cup cannot be pressed all the way out of the end yoke, remove it
with vise grip or channel lock pliers.
4. Reposition the tool 180 degrees to PRESS on the spider and remove the remaining bearing cup from the opposite side.
5. Remove the spider and circular flange from the halfshaft end yoke.
6. Remove the spider from the circular flange in the same manner.
7. Clean all foreign matter from the yoke area at the inboard side of the halfshaft.
Outboard Constant Velocity Joint
1. Clamp halfshaft in a vise. Do not allow vise jaws to contact the boot or its clamp.
NOTE: The vise should be equipped with jaw caps to prevent damage to any machined surfaces.
2. Remove the slip yoke boot clamps and separate the outboard shaft and joint assembly from the inboard slip yoke assembly. Remove the slip yoke
boot and discard the boot.
3. Cut the large boot clamp using side cutters and peel away from the boot. After removing the clamp, roll boot back over shaft, remove and discard
the boot.
4. Clean all parts in a suitable parts cleaning solvent.
CAUTION: Do not submerge slip yoke assembly U-Joint in cleaning solvents.
5. Inspect Constant Velocity (CV) Joint and slip yoke assembly for excessive wear, pitting, rust, and broken parts. If inspection determines that the
CV-Joint is unusable, the complete outer shaft assembly must be replaced.