ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

Outer Constant Velocity (CV) Joint Boot > < Intermediate Shaft
Front Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot Transit/Tourneo Connect 2002.5 (06/2002-)
Removal and Installation

Special Tool(s)

Boot clamp tightening tool

204-169 (14-044)

Separating tool, bearing/gear wheel

205-310 (15-091)

Puller, bearing/gear wheel

205-311 (15-092)

Installer, bushing and oil seal, transmission extension

308-046 (16-016)

General Equipment
Grip wrench (Hazet 1847-1)
Expanding pliers, snap-ring
Materials
Name
Specification
Grease, inner joint
XS4C-M1C230-BA 

Removal

  1. Remove the drive halfshaft.
    For additional information, refer to Left-hand drive halfshaft /
    Right-hand drive halfshaft in this section.

  1. CAUTION:
    CAUTION:Use a vice with protective jaw covers.
    NOTE:
    NOTE:Hold the intermediate shaft in a vice.
    Clamp the constant velocity joint into the vice and detach the tripod housing.
    1. Cut and discard the boot clamps.
    1. Slide the boot back.

  1. Pull apart the tripod joint.
    • Remove the grease.

  1. Remove the snap-ring.

  1. Detach the tripod using the special tool.
    • Take off the boot and discard it.

Installation

  1. Insert a new boot.

  1. NOTE:
    NOTE:Renew the boot clamp.
    Install a new inner boot clamp using the special tool.

  1. NOTE:
    NOTE:Chamfer points towards front drive halfshaft.
    Attach the tripod using the special tool.
    • Slide on the boot.
    • Drive the tripod home onto the front drive halfshaft.

  1. NOTE:
    NOTE:Use a new snap-ring.
    Install the tripod snap-ring.
  1. CAUTION:
    CAUTION:The constant velocity joint must not be packed with more than 120 g of grease.
    Pack the constant velocity joint with grease .

  1. Assemble the constant velocity joint.
    1. Slide a small screwdriver under the boot seat to allow the air to escape.
    1. Slide the constant velocity joint in as far as it will go, then pull it back out 20 mm.

  1. NOTE:
    NOTE:Renew the boot clamp.
    Install a new outer boot clamp using a grip wrench .
  1. Install the drive halfshaft.
    For additional information, refer to Left-hand drive halfshaft /
    Right-hand drive halfshaft in this section.

Outer Constant Velocity (CV) Joint Boot > < Intermediate Shaft