Log In
Search suggestions

    My Vehicles

    1992 Pontiac Grand Prix 3.1L MFI OHV 6cyl

    My Store

    1720 S RIDGEWOOD A
    (386) 427-1210

    OPEN 'til 9:00 PM today

    GET A $25 GIFT CARD FOR EVERY $100 SPENT ON ONLINE SHIP-TO-HOME ORDERS.

    Use Code: GIFTME

    See Details

    Ford Taurus/Sable 1986-1995 Repair Information

    CV-Joint

    Print

    REMOVAL & INSTALLATION



    Outboard CV-Joint

    See Figures 1 through 26

    1. Disconnect the negative battery cable. Raise and safely support the vehicle.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of the outboard CV-joint assembly



    Click image to see an enlarged view

    Fig. Fig. 2: Before removal, check the CV-boot for wear or damage



    Click image to see an enlarged view

    Fig. Fig. 3: Clean the CV-joint prior to removing the boot, but be careful not to damage anything

    1. Remove the halfshaft assembly from the vehicle. For details, please refer to the procedure located earlier in this section.
    2.  
    3. Clamp the halfshaft in a vise that is equipped with soft jaw covers. Do not allow the vise jaws to contact the boot or boot clamp.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 4: Clamp the halfshaft in a vise with soft jaw covers, but do not allow the vise jaws to contact the boot or boot clamp

    1. Cut the boot clamp with a pair of side cutters, then pull the clamp away from the boot. Slide the boot back over the shaft after the clamp has been removed.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 5: Cut the boot clamp with a pair of side cutters, then pull the clamp away from the boot



    Click image to see an enlarged view

    Fig. Fig. 6: Slide the boot back over the shaft once the clamp has been removed

    1. Support the interconnecting shaft in a soft jawed vise and angle the CV-joint pointing downward so the inner bearing race is exposed.
    2.  

    1. Use a brass drift and hammer, give a sharp tap to the inner bearing race to dislodge the internal driveshaft bearing retainer circlip and separate the CV-joint from the interconnecting shaft. Make sure to secure the CV-joint so it does not drop after separation.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 7: Using a brass drift and hammer, give a sharp tap to the inner bearing race to dislodge the internal driveshaft bearing retainer circlip and separate the CV-joint from the interconnecting shaft. Make sure to secure the CV-joint so it does not drop after separation. The boot cannot be removed from the shaft

    1. Remove the boot from the shaft.
    2.  
    3. Inspect the CV-joint grease for contamination. If the CV-joints are working correctly, and the grease doesn't seem to be contaminated, add grease, then replace the CV-joint boot.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 8: Check the CV-joint grease for contamination or foreign debris by visually inspecting it and rubbing it with fingers. Any grittiness indicates contamination

    1. If the lubricant appears to be contaminated, proceed with a complete CV-joint disassembly.
    2.  

    Do NOT reuse the circlip. Replace the used circlip with a new one before assembly.

    1. Remove and discard the circlip located near the end of the interconnecting shaft. The stop ring, located just below the circlip should be removed and replaced only if damaged or worn.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 9: The stop ring, located just below the circlip, should be removed and replaced only if damaged or worn

    The vise must be equipped with soft jaw covers to avoid damaging the shaft splines.

    1. Clamp the CV-joint in a vise with soft jaw covers, with the outer face pointing upward. Be careful not to damage the dust shield.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 10: Clamp the CV-joint in a vise with soft jaw covers, with the outer face facing up. Be careful not to damage the dust shield



    Click image to see an enlarged view

    Fig. Fig. 11: Vise jaw caps are made of copper, brass, wood or other soft material. They are slipped over the steel jaws of the vise so the finished surfaces of the component won't get scratched or nicked

    1. Press down on the inner race until it tilts enough to permit removal of the ball. A tight assembly can be tilted by tapping the inner race with a wooden dowel and hammer, but do not hit the cage.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 12: Press down on the inner race until it tilts enough to permit removal of the ball. A tight assembly can be tilted by tapping the inner race with a wooden dowel and hammer, but do not hit the cage


    WARNING
    Be careful not to scratch or damage the inner race or cage spheres.

    1. With the cage sufficiently tilted, remove the ball from the cage. Repeat this until all of the balls are removed. If the balls are tight in the cage, use a blunt edged prytool to pry the balls from the cage.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 13: With the cage sufficiently tilted, remove a ball from the cage. Repeat this until all of the balls are removed. If the balls are tight in the cage, use a blunt edged prytool to pry the balls from the cage

    1. Pivot the cage and inner race assembly until it is straight up and down in the outer race. Align the cage windows with the outer race lands while pivoting the bearing cage.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 14: Pivot the cage and inner race assembly until it is straight up and down in the outer race. Align the cage windows with the outer race lands while pivoting the bearing cage

    1. With the cage pivoted and aligned, lift the assembly from the outer race. Rotate the inner race up and out of the cage.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 15: With the cage pivoted and aligned, lift the assembly from the outer race. Rotate the inner race up and out of the cage

    To install:
    1. Apply a light coating of Ford High Temperature Constant Velocity Joint Grease E43Z-19590-A or equivalent, on the inner and outer ball races.
    2.  
    3. Install the inner race in the bearing cage.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 16: Install the inner race in the bearing cage

    1. Install the inner race and cage assembly in the outer race. Install the assembly vertically, then pivot 90° into position.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 17: Install the inner race and cage assembly in the outer race. Install the assembly vertically, then pivot 90° into position

    1. Align the bearing cage and inner race with the outer race. Tilt the inner race and cage, then install a ball. Repeat until all balls are installed.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 18: Align the bearing cage and inner race with the outer race. Tilt the inner race and cage, then install a ball. Repeat until all balls are installed

    1. On some vehicles, the left and right interconnecting shafts are different, depending on year and vehicle application. The outboard end of the shaft is shorter from the end of the shaft to the end of the boot groove than the inboard end. Take a measurement to insure correct installation.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 19: On some vehicles, the left and right interconnecting shafts are different, depending on year and vehicle application. The outboard end of the shaft is shorter from the end of the shaft to the end of the boot groove than the inboard end. Take a measurement to insure correct installation

    1. If removed, install the CV-joint boot after removing the stop ring. Make sure the CV boot is seated in its groove and the clamp is in position using Boot Clamp Installer T95P-3514-A or equivalent. Tighten the tool through the bolt until it's in a closed position, then remove the tool.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 20: Make sure the CV boot is seated in its groove and the clamp is in position using Boot Clamp Installer T95P-3514-A or equivalent. Tighten the tool through the bolt until it's in a closed position, then remove the tool

    1. If removed, install the stop ring. If not removed, make sure the ring is properly seated in its groove.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 21: If removed, install the stop ring. If not removed, make sure the ring is properly seated in its groove

    1. Install a new circlip in the groove nearest the end of the shaft by starting one end in the groove, then work the circlip over the inboard CV joint stub shaft pilot bearing housing end and into the groove. This will avoid overexpanding the circlip.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 22: Install a new circlip in the groove nearest the end of the shaft by starting one end in the groove, then work the circlip over the inboard CV joint stub shaft pilot bearing housing end and into the groove. This will avoid overexpanding the circlip

    1. Before positioning the boot over the CV-joint, pack the joint and boot with Ford High Temperature Constant Velocity Joint Grease E43Z-19590-A or equivalent. Pack the joint with grease. Any remaining grease in the tube is to be spread evenly inside of the boot.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 23: Pack the CV-joint with grease. Any leftover grease in the tube should be spread evenly inside of the boot

    1. With the front wheel driveshaft joint boot held back, position the CV-joint on the shaft and tap into position using a plastic tipped hammer.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 24: With the front wheel driveshaft joint boot held back, position the CV-joint on the shaft and tap into position using a plastic tipped hammer

    1. The CV-joint is fully seated when the circlip locks in the groove cut into the CV-joint inner race. Check for seating by trying to pull the joint away from the shaft.
    2.  
    3. Remove all excess grease from the CV-joint external surfaces and mating boot surface. Position the boot over the joint.
    4.  
    5. Before installing the boot clamp, make sure all air pressure that may have built up in the boot is removed. Pry up on the boot lip to allow the air to escape.
    6.  
    7. Position the boot over the joint, then make sure the boot is seated in its groove and the clamp is in position using Boot Clamp Installer T95P-3514-A or equivalent. Position the tool on the clamp ear, then tighten the tool through the bolt, until it is in the closed position. Remove the tool.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 25: Make sure the boot is seated in its groove and the clamp is in position, using Boot Clamp Installer T95P-3514-A or equivalent



    Click image to see an enlarged view

    Fig. Fig. 26: Position the tool on the clamp ear and tighten the tool through the bolt, until it is in the closed position, then remove the tool

    1. Install the halfshaft assembly and lower the vehicle. Connect the negative battery cable.
    2.  

    Inboard CV-Joint
    1986-92 VEHICLES

    See Figures 27, 28, 29, 30, 31 and 32

    1. Disconnect the negative battery cable. Raise and safely support the vehicle.
    2.  
    3. Remove the halfshaft assembly from the vehicle.
    4.  
    5. Clamp the halfshaft in a vise that is equipped with soft jaw covers. Do not allow the vise jaws to contact the boot or boot clamp.
    6.  
    7. Cut and remove both boot clamps, then slide the boot back on the shaft. Remove the clamp by engaging the pincer jaws of boot clamp pliers D87P-1090-A or equivalent, in the closing hooks on the clamp and draw together. Disengage the windows and locking hooks, then remove the clamp.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 27: Cut and remove both boot clamps, then slide the boot back on the shaft

    1. Mark the position of the outer race in relation to the shaft, then remove the outer race from the tripod.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 28: Slide the outer race off of the tripod

    1. Move the stop ring back on the shaft using snapring pliers. Move the tripod assembly back on the shaft to allow access to the circlip.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 29: Move the stop ring back on the shaft using snapring pliers, then ...



    Click image to see an enlarged view

    Fig. Fig. 30: ... move the tripod assembly back on the shaft to allow access to the circlip

    1. Remove and discard the circlip from the shaft, then replace with a new one during installation. Mark the position of the tripod on the shaft and remove the tripod assembly. Remove the boot.
    2.  
    3. Check the CV-joint grease for contamination. If the CV-joints are operating properly and the grease is not contaminated, add grease and replace the boot. If the grease appears contaminated, disassemble the CV-joint and clean or replace, as necessary.
    4.  

    To install:
    1. Install the CV-joint boot. Make sure the boot is seated in the boot groove on the shaft. Tighten the clamp using crimping pliers, but do not tighten to the point where the clamp bridge is cut or the boot is damaged.
    2.  
    3. Install the tripod assembly with chamfered side toward the stop ring. If the tripod is being reused, align the marks that were made during the removal procedure.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 31: Install the tripod assembly with its chamfered side toward the stop ring

    1. Install a new circlip. Compress the circlip and slide the tripod assembly forward over the circlip to expose the stop ring groove.
    2.  
    3. Move the stop ring into the groove using snapring pliers, making sure it is fully seated in the groove.
    4.  
    5. Fill the CV-joint outer race and CV-boot with grease. Install the outer race over the tripod assembly, aligning the marks made during the removal procedure.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 32: Fill the CV-joint outer race and CV-boot with grease

    1. Remove all excess grease from the CV-joint external surfaces and mating boot surface. Position the boot over the CV-joint making sure the boot is seated in the groove. Move the CV-joint in and out, as necessary, to adjust the length to the following specifications:

      Automatic transaxle left halfshaft, except 1986-90 Taurus with 2.5L engine-18.27 in. (464mm)
       
      Automatic transaxle right halfshaft, except 1986-90 Taurus with 2.5L engine-23.58 in. (599mm)
       
      Automatic transaxle left halfshaft, 1986-90 Taurus with 2.5L engine-22.80 in. (579mm)
       
      Automatic transaxle right halfshaft, 1986-90 Taurus with 2.5L engine-20.09 in. (510mm)
       
      Manual transaxle left halfshaft-21.24 in. (539.5mm)
       
      Manual transaxle right halfshaft-21.63 in. (549.5mm)
       

    2.  
    3. Before installing the boot clamp, make sure any air pressure that may have built up in the boot is relieved. Insert a small prybar between the boot and outer race to allow the trapped air to escape. Release the air only after adjusting the length dimension.
    4.  
    5. Seat the boot in the groove and clamp in position using crimping pliers D87P-1098-A or equivalent. Install the clamp as follows:
      1. With the boot seated in the groove, place the clamp over the boot.
      2.  
      3. Engage hook C in the window.
      4.  
      5. Place the pincer jaws of the crimping pliers in closing hooks A and B.
      6.  
      7. Secure the clamp by drawing the closing hooks together. When windows 1 and 2 are above locking hooks D and E, the spring tab will press the windows over the locking hooks and engage the clamp.
      8.  

    6.  
    7. Install the halfshaft and lower the vehicle. Connect the negative battery cable.
    8.  

    1993-95 VEHICLES EXCEPT 3.2L SHO

    See Figures 33, 34, 35, 36, 37, 38 and 39

    On this design, the tripod assembly cannot be removed from the interconnecting shaft. If a tripod assembly, or interconnecting shaft is required, a driveshaft and joint assembly must be used. But if CV-joint boots or boot clamps are needed, they are available separately.

    1. Disconnect the negative battery cable. Raise and safely support the vehicle.
    2.  
    3. Remove the halfshaft assembly from the vehicle.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 33: Exploded view of the driveshaft and CV-joint-1993-95 vehicles except 3.2L SHO

    1. Clamp the halfshaft in a vise that is equipped with soft jaw covers. Do not allow the vise jaws to contact the boot or boot clamp.
    2.  
    3. Cut and remove both boot clamps, then slide the boot back on the shaft. Remove the clamp by engaging the pincer jaws of boot clamp pliers D87P-1090-A or equivalent, in the closing hooks on the clamp and draw together. Disengage the windows and locking hooks, then remove the clamp.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 34: Removing the clamp using Boot Clamp Pliers D87P-1090-A

    1. Slide the inboard CV-joint housing off of the tripod.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 35: Slide the inboard CV-joint housing off of the tripod

    1. When replacing damaged boots, the grease should be checked for contamination. If the CV-joints are operating satisfactorily, and the grease does not seem to be contaminated, add grease, then replace the boot. If the grease is contaminated, you will have to proceed with a complete CV-joint disassembly and inspection.
    2.  
    3. If further disassembly is required, remove the outboard CV-joint and boot as described earlier in this section.
    4.  
    5. Remove the driveshaft joint stop ring and bearing retainer circlip.
    6.  
    7. Slide the inboard boot off of the interconnecting shaft.
    8.  
    9. Remove the trilobe insert from the CV-joint stub. Remove the grease from the outer race, then inspect the outer race and tripod assembly.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 36: Remove the trilobe insert from the CV-joint stub

    To install:
    1. Install the boot on the interconnecting halfshaft. Position the boot to allow for the CV-joint housing installation.
    2.  
    3. Install the trilobe insert on the CV-joint housing positioning in the groove on the outer race.
    4.  
    5. Fill the CV-joint housing with Ford High Temperature Constant Velocity Grease E43Z-19590-A or equivalent, and spread remaining grease evenly inside of the joint boot. The total fill amount is 9 oz. (250 grams).
    6.  



    Click image to see an enlarged view

    Fig. Fig. 37: Filling the housing with CV-joint grease

    1. Install the CV-joint on the tripod assembly.
    2.  
    3. Before installing the boot clamp, make sure any air pressure that may have built up in the boot is relieved. Insert a small prybar between the boot and outer race to allow the trapped air to escape. Release the air only after adjusting the length dimension.
    4.  
    5. Remove all excess grease from the CV-joint external surfaces and mating boot surface. Position the boot over the CV-joint making sure the boot is seated in the groove. Move the CV-joint in and out, as necessary, to adjust the length to the specifications in the accompanying figure.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 38: Installation and lubrication specifications

    All vehicles, except SHO vehicles, require a reusable low profile large front CV-joint boot clamp on the right-hand side inboard CV-joint.

    1. Seat the boot in the grooves, then clamp in position using Boot Clamp Installer T94P-3514-A or equivalent, on the left CV-joint housing.
    2.  
    3. Install the large low profile right-hand boot clamp as follows:
      1. With the boot seated in the groove, place the clamp over the boot.
      2.  
      3. Engage hook C in the window.
      4.  
      5. Place the pincer jaws of the crimping pliers in closing hooks A and B.
      6.  
      7. Secure the clamp by drawing the closing hooks together. When windows 1 and 2 are above locking hooks D and E, the spring tab will press the windows over the locking hooks and engage the clamp.
      8.  

    4.  
    5. Position Boot Clamp Installer Tool T95P-3514-A or equivalent, on the clamp ears, then tighten the tool through the bolt until the tool is in the closed position. Remove the tool.
    6.  

    Do not overexpand or twist the circlip during installation. ALWAYS replace the circlip with a new one during installation.

    1. On the right-hand side inboard CV-joint housing, install a new circlip, in the groove nearest the end of the shaft by starting one end in the groove, then working the circlip over the stub shaft and into the groove.
    2.  
    3. Work the CV-joint through its full range of travel at various angles. The joint should flex, extend and compress smoothly.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 39: Work the CV-joint through its full range of travel at various angles. The joint should flex, extend and compress smoothly

    1. Install the halfshaft assembly, then carefully lower the vehicle.
    2.  
    3. Connect the negative battery cable.
    4.  

    3.2L SHO

    See Figures 40, 41, 42, 43, 44, 45, 46, 47 and 48

    The inboard CV-joint assembly on these vehicles is permanently retained to the interconnecting shaft. The service CV-joint includes the shaft and CV-joint boot. The boot or driveshaft and joint replacement will necessitate removal of the CV-joint and boot.

    1. Disconnect the negative battery cable. Raise and safely support the vehicle.
    2.  
    3. Remove the halfshaft assembly from the vehicle.
    4.  
    5. Clamp the halfshaft in a vise that is equipped with soft jaw covers. Do not allow the vise jaws to contact the boot or boot clamp.
    6.  
    7. Cut and remove both of the CV-joint boot clamps.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 40: Removing the boot clamps using pliers

    1. Slide the boot back on the shaft, then wipe the grease away from the CV-joint.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 41: After sliding the boot back on the shaft, wipe away the grease from the CV-joint

    1. When replacing damaged boots, the grease should be checked for contamination. If the CV-joints are operating satisfactorily, and the grease does not seem to be contaminated, add grease, then replace the boot. If the grease is contaminated, you will have to proceed with a complete CV-joint disassembly and inspection.
    2.  
    3. If further disassembly is required, remove the driveshaft and CV-joint, and the boot.
    4.  
    5. Remove the driveshaft stop ring and bearing retainer circlip, the slide the joint boot off of the interconnecting shaft.
    6.  

    To install:
    1. Install the CV-joint boot on the interconnecting shaft. Position the boot to allow for inboard CV-joint housing installation.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 42: Installing the CV-joint boot on the interconnecting shaft; make sure to position the boot to allow for CV-joint housing installation

    1. Position the CV-joint boot in the small boot groove. Using Boot Clamp Installer T95P-3514-A or equivalent, move the small boot clamp in position. Tighten the tool through the bolt until the tool is in the closed position.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 43: Using the boot clamp installer to fasten the small boot clamp

    1. Using Ford High Temperature Constant Velocity Grease E43Z-19590-A or equivalent, fill the inboard CV-joint with grease, then spread the remaining grease evenly inside of the boot.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 44: Filling the CV-joint and boot with grease

    1. Before installing the boot clamp, make sure any air pressure that may have built up in the boot is relieved. Insert a small prybar between the boot and outer race to allow the trapped air to escape. Release the air only after adjusting the length dimension.
    2.  
    3. Remove all excess grease from the external CV-joint surfaces, and boot sealing surfaces. Slide the CV-joint boot into position on the inboard CV-joint housing. Move the CV-joint in and out, as necessary, to adjust to the specified length shown in the accompanying figure.
    4.  
    5. Locate the clamp tabs in the slots, then make the clamps as tight as possible by hand.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 45: After positioning the clamp tabs in the slots, make the clamps as tight as possible by hand

    1. Make sure the boot is seated in its groove and the clamp is in position. Position the Boot Clamp Replacer T95T-3514-A or equivalent on the clamp ear, then tighten the tool through the bolt until the tool is in a closed position.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 46: Position the Boot Clamp Replacer T95T-3514-A or equivalent, on the clamp ear, then tighten the tool through the bolt until the tool is in a closed position

    1. Work the CV-joint through its full range of travel at various angles. The joint should flex, extend and compress smoothly.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 47: Work the CV-joint through its full range of travel at various angles. The joint should flex, extend and compress smoothly

    Do not overexpand or twist the circlip during installation. ALWAYS replace the circlip with a new one during installation.

    1. Install a new circlip, in the groove nearest the end of the shaft by starting one end in the groove, then working the circlip over the stub shaft and into the groove.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 48: Do not overexpand or twist the circlip during installation. ALWAYS replace the circlip with a new one during installation

    1. Install the halfshaft assembly, then carefully lower the vehicle.
    2.  
    3. Connect the negative battery cable.
    4.  

     
    AutoZone Logo