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206 Brake System > < Halfshaft - Vehicles Built From: 12-2004

Maverick 2005 (08.2004-)

Rear Drive Halfshafts - Halfshaft Joint—Vehicles Built From: 12/2003 Maverick 2005 (08/2004-)
Disassembly and Assembly

Special Tool(s)

CV Boot Clamp Installer

205-343(T95P-3514-A)
Materials
Name
Specification
Constant Velocity Joint Grease (High Temperature)
XG-5
WSS-M1C258-A1

Disassembly

CAUTION:
CAUTION:Never pick up or hold the halfshaft by only the inner or outboard CV joint.
CAUTION:
CAUTION:Handle the halfshaft by only the interconnecting shaft to avoid pull-apart and potential damage to the CV joints.
CAUTION:
CAUTION:Do not over-angle the CV joints.
CAUTION:
CAUTION:Damage will occur to an assembled inner CV joint if it is over-plunged outward from the joint housing.
CAUTION:
CAUTION:Never use a hammer to remove or install the halfshafts.
CAUTION:
CAUTION:Never use the halfshaft assembly as a lever to position other components. Always support the free-ends of the halfshaft.
CAUTION:
CAUTION:Do not allow the boots to contact sharp edges or hot exhaust components.
CAUTION:
CAUTION:Do not drop assembled halfshafts. The impact may cut the boots from the inside without evidence of external damage.
  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 2 inner halfshaft boot clamps.
  1. Slide the inner halfshaft boot off the inner CV joint housing.

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

  1. Using a soft face hammer, separate the halfshaft from the inner joint housing.
  1. Remove and discard the bearing retainer circlip.
  1. Remove and discard the snap ring.
  1. Remove the inner halfshaft boot from the halfshaft.
  1. Remove the 2 outer halfshaft boot clamps.
  1. Slide the outer halfshaft joint boot back out of the way exposing the outer CV joint.

  1. If reinstalling the original inner CV joint, mark the outer CV joint and the halfshaft to be sure of correct installation.

  1. Using a soft-face hammer, separate the outer CV joint by gently tapping it off the halfshaft.
  1. Remove and discard the bearing retainer circlip.
  1. Remove the snap ring from the halfshaft.
  1. Slide the outer halfshaft boot off the halfshaft.

Assembly
  1. Lubricate the inner and outer CV joints with joint grease.
  1. Install the outer halfshaft boot.
  1. Install the snap ring on the halfshaft.
  1. Install a new halfshaft bearing retainer circlip.

  1. Using a soft-face hammer, install the inner CV joint by gently tapping it onto the halfshaft.
  1. Remove any excess grease on the mating surfaces and slide the outer halfshaft joint boot forward onto the outer CV joint.
  1. Remove any excess air trapped in the outer halfshaft boot using a cloth-covered screwdriver after adjusting the outer halfshaft boot spacing.

  1. Using the special tool, install 2 new outer halfshaft boot clamps.
  1. Position the inner halfshaft boot.
  1. Install the snap ring.
  1. Install the bearing retainer circlip.

  1. Using a soft face hammer, install the halfshaft on the inner CV joint.
  1. Position the inner halfshaft boot.
  1. Remove any excess air trapped in the inner halfshaft boot using a cloth-covered screwdriver after adjusting the inner halfshaft boot spacing.

  1. Using the special tool, install 2 new inner CV joint boot clamps.
  1. Install the halfshaft. For additional information, refer to Halfshaft in this section.

206 Brake System > < Halfshaft - Vehicles Built From: 12-2004