ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Halfshaft Joint > < Intermediate Shaft

Maverick 2001 (12.2000-07.2004)

Front Drive Halfshafts - Halfshaft Maverick 2001 (12/2000-07/2004)
Disassembly and Assembly

Special Tool(s)

CV Boot Clamp

205-343 (T95P-3514-A)

Disassembly

  1. Remove the halfshaft. For additional information, refer to Halfshaft in this section.

  1. Secure the halfshaft and constant velocity (CV) joint in a vise using protective jaw covers.

  1. Remove the inboard halfshaft boot clamps.

  1. Slide the inboard halfshaft boot off the inboard CV joint housing.

  1. Separate the tripod joint from the inboard CV joint housing.

  1. If reinstalling the original tripod joint, mark the tripod joint and the halfshaft to make sure of correct installation.

  1. Remove the snap ring.

  1. Remove the tripod joint.

  1. Remove the inboard halfshaft boot from the halfshaft.

  1. Remove the two outboard halfshaft boot clamps.

  1. Slide the outboard halfshaft joint boot back out of the way exposing the outboard CV joint.

  1. If reinstalling the original outboard CV joint, mark the outboard CV joint and halfshaft to make sure of correct installation.

  1. Use a soft-face hammer to separate the outboard CV joint by gently tapping it off the halfshaft.

  1. Remove the halfshaft bearing retainer circlip and discard.

  1. Slide the outboard halfshaft boot off of the halfshaft.

Assembly

NOTE:
NOTE:Make sure all components are clean and free of foreign material.
  1. Lubricate the outboard CV joint with Ford High Temperature Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A.

  1. Install the outboard halfshaft boot.

  1. Install a new halfshaft shaft bearing retainer circlip.

  1. Use a soft-face hammer to install the inboard CV joint by gently tapping it onto the halfshaft.

  1. Remove any excess grease on the mating surfaces and slide the outboard halfshaft joint boot forward onto the outboard CV joint.

  1. Remove any excess air trapped in the outboard halfshaft boot using a cloth covered screwdriver after adjusting the outboard halfshaft boot spacing.

  1. Using the special tool, install two new outboard halfshaft boot clamps.

  1. Position the inboard halfshaft boot.

  1. Install the tripod joint on the halfshaft.
    1. Line up the marks on the halfshaft and tripod joint.
    1. Install the tripod joint on the halfshaft.

  1. Install the snap ring.

  1. Lubricate the three tripod joint needle bearings.
    • Use Ford High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207A.

  1. Fill the tripod joint housing with Ford High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207A.

  1. Position the tripod housing onto the tripod.

  1. Position the inboard halfshaft boot.
    1. Position the inboard halfshaft boot.
    1. Position the inboard halfshaft boot clamp.

  1. Remove any excess air trapped in the halfshaft boot using a cloth covered screwdriver after adjusting the halfshaft boot spacing.

  1. Using the special tool, install two new outboard joint boot clamps.
  1. Install the front wheel halfshaft. For additional information, refer to Halfshaft in this section.

Halfshaft Joint > < Intermediate Shaft