Contour V6-153 2.5L DOHC (1996)
Constant Velocity Joint: Service and Repair
Outboard
NOTE: The outer CV joint is composed of matched components. Interchanging components is not recommended.
REMOVAL
1. Place driveshaft assembly into a suitable soft jaw vise.
2. Remove both clamps from inner joint boot.
3. Pull large end of boot back and off joint assembly.
Fig. 6 Separating Constant Velocity Joint From Shaft
4. Support driveshaft assembly in soft jaw vice as shown, then tap on inner race of joint using a suitable drift punch to release driveshaft bearing
retainer circlip.
5. Slide joint assembly off shaft splines to expose driveshaft bearing retainer circlip.
6. Remove and discard driveshaft bearing retainer circlip.
7. Remove joint boot from shaft.
INSPECTION
1. Clean and dry all components.
2. Inspect boot for cracks, splits and abrasion.
3. Inspect joint components for wear, cracks and broken parts.
4. Inspect shaft for worn splines and deformities.
INSTALLATION
1. Place small boot clamp on shaft, then slide boot onto shaft and into position groove on shaft.
2. Place small clamp into position on boot, then using suitable boot clamp ring pliers, tighten clamp ring securely.
CAUTION: Do not overtighten clamp ring or cut or deform boot.
3. Place a new driveshaft bearing retainer circlip onto shaft. Use caution not to stretch or deform circlip during installation.
4. Place driveshaft in a vertical position in soft jaw vise.
5. Fill joint housing and boot with suitable quantity and type CV joint grease.
6. Place joint on driveshaft, aligning splines, then tap joint onto shaft using a soft face hammer, until driveshaft bearing retainer circlip engages joint.
7. Position boot onto outer joint.
8. Ensure boot is in a relaxed position (not stretched, compressed or dimpled). If necessary, pry up edge of boot using a blunt flat tool and allow air
pressure to equalize. This ensures proper joint positioning.
9. Clean any excess grease from outside of joint and boot.
10. Place large clamp into position on boot, then using suitable boot clamp ring pliers, tighten clamp ring securely.
