Quest 1995-1996

CV-Joints

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Inspection



Specific to:

Mercury Villager 1993-2000

Nissan Quest 1993-2000

Nissan recommends CV (Constant Velocity) boot inspection every 15,000 miles (12,000 km) or 12 months, whichever comes first, on normal use vehicles. The recommended inspection interval for severe use vehicles is every 7,500 miles (12,000 km) or 6 months, whichever comes first, however, CV boots should be checked for damage each time the oil is changed and any other time the vehicle is raised for service. These boots keep water, grime, dirt and other damaging matter from entering the CV-joints. Any of these could cause early CV-joint failure which can be expensive to repair. Heavy grease thrown around the inside of the front wheel(s) and on the brake caliper/drum can be an indication of a torn boot. Thoroughly check the boots for missing clamps and tears. If the boot is damaged, it should be replaced immediately. Please refer to Drive Train, Automatic Transaxle, Halfshafts, CV-Joint Overhaul for the procedure.

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Fig. CV-boots must be inspected periodically for damage



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Fig. A torn boot should be replaced immediately

Overhaul



Specific to:

Mercury Villager 1993-2000

Nissan Quest 1993-2000

The Mercury Villager and Nissan Quest use two types of joints. The inboard joints are double offset joints. The outboard joints are Rzeppa joints. Be sure to properly identify the joint before attempting joint or boot replacement.

The distance between the large and small boot bands is important and should be checked prior to and after boot service. This is so the boot will not be installed either too loose or too tight, which could cause early wear and cracking, allowing the grease to get out and water and dirt in, leading to early joint failure.


NOTE
The driveshaft joints use special grease; do not add any grease other than that supplied with the kit.



Click image to see an enlarged view

Fig. Exploded view of the left halfshaft assembly



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Fig. Exploded view of the right halfshaft assembly

Double Offset Joint

Specific to:

Mercury Villager 1993-2000

Nissan Quest 1993-2000

The double offset joint is bigger than other joints and, in these applications, is used as an inboard joint.

  1. Remove the halfshaft from the vehicle.
  2.  
  3. Remove the inboard boot clamps. Side cutter pliers can be used to cut the metal retaining bands. Remove the boot from the joint outer race.

    Click image to see an enlarged view

    Fig. Removing the inner band from the CV-boot

  4.  
  5. Locate and remove the large circlip at the base of the joint. Remove the outer race (the body of the joint).
  6.  
  7. Remove the six ball bearings from the cage.
  8.  
  9. Remove the small snapring and take off the inner race and cage. Use a suitable puller, if necessary, to remove the inner race from the shaft.

    Click image to see an enlarged view

    Fig. Removing the inboard CV-joint snapring



    Click image to see an enlarged view

    Fig. Using a puller to remove the inboard CV-joint inner race

  10.  
  11. If the boot is to be reused, wipe the grease from the splines and wrap the splines in vinyl tape before sliding the boot from the shaft.
  12.  
  13. Remove the inboard boot from the shaft. If the outboard boot is to be replaced, remove the boot retainer rings, and slide the boot down and off of the shaft at this time. If the outboard boot is to be replaced on the left halfshaft, mark the location of the dynamic damper, remove the damper retainer rings, and remove the damper.
  14.  

To install:

  1. Clean the cage, ball bearings, and inner and outer races in solvent. Dry the parts thoroughly and inspect them. If any part is damaged or worn, the CV-joint assembly must be replaced.
  2.  
  3. Be sure to tape the shaft splines before installing the boots. Fill the inside of the boot with the specified grease and install the boot(s) and dynamic damper, if removed. Often the grease supplied in the replacement parts kit is meant to be divided in half, with half being used to lubricate the joint and half being used inside the boot.
  4.  
  5. Install the cage onto the halfshaft so that the small diameter side of the cage is installed first. With a brass drift, tap lightly and evenly around the inner race to install the race until it comes into contact with the rib of the shaft.
  6.  
  7. Install the snapring.
  8.  
  9. Apply the specified grease to the inner race and cage and fit them together. Insert the ball bearings into the cage.
  10.  
  11. Install the outer race (the body of the joint) after filling with the specified grease. The outer race should be filled with this grease.
  12.  
  13. Install the boots and tighten the boot bands securely. Make sure the distance between the boot bands is correct.
  14.  
  15. Install the halfshaft in the vehicle.
  16.  

Rzeppa Joint

Specific to:

Mercury Villager 1993-2000

Nissan Quest 1993-2000

  1. Remove the halfshaft from the vehicle.
  2.  
  3. Remove the outboard boot clamps. Side cutter pliers can be used to cut the metal retaining bands. Slide the boot back on the shaft.
  4.  
  5. Position the halfshaft in a vice at an angle to expose the outboard CV-joint inner race.
  6.  
  7. Using a brass drift and hammer, sharply tap the inner race to release the internal circlip, and slide the outboard CV-joint assembly from the halfshaft.

    Click image to see an enlarged view

    Fig. Using a brass drift to remove the outboard CV-joint from the halfshaft

  8.  
  9. Remove the circlip from the halfshaft and discard it. DO NOT remove the stop ring from the halfshaft unless it is damaged or worn, and requires replacement.

    Click image to see an enlarged view

    Fig. Always replace the circlip when the outboard CV-joint has been disassembled

  10.  
  11. Position the outboard CV-joint in a vise, being careful not to damage the shaft or splines.
  12.  
  13. Using a brass drift and plastic or rubber mallet, gently tap the inner race opposite of one of the ball bearings. When the inner race is tilted sufficiently, remove the ball bearing.

    Click image to see an enlarged view

    Fig. Gently tap the inner race into position for ball bearing removal

  14.  
  15. Repeat the previous step until all of the ball bearings have been removed.
  16.  
  17. Rotate the inner race and cage until they are straight up and down in the outer race. Remove the inner race and cage from the outer race.

    Click image to see an enlarged view

    Fig. Removing the inner race and cage from the outer race

  18.  
  19. Rotate the inner race out of the cage.
  20.  
  21. If the boot is be reused, wrap vinyl tape around the spline part of the shaft so the boot will not be damaged when removed. Remove the boot from the shaft.
  22.  

To install:

  1. Clean the cage, ball bearings, and inner and outer races in solvent. Dry the parts thoroughly and inspect them. If any part is damaged or worn, the CV-joint assembly must be replaced.
  2.  
  3. Install the inner race into the cage, rotating the race until it is properly positioned.
  4.  
  5. Install the inner race and cage into the outer race, making sure that the beveled side of the inner race faces out.
  6.  
  7. Align the inner race and cage window with the outer race ball bearing land.
  8.  
  9. Tilt the inner race and cage far enough to install a ball bearing.
  10.  
  11. Repeat the previous step until all of the ball bearings have been installed.
  12.  
  13. Pack the outboard CV-joint with the specified grease, moving the inner race, cage, and ball bearings enough to ensure adequate coverage. Often the grease supplied in the replacement parts kit is meant to be divided in half, with half being used to lubricate the joint and half being used inside the boot.
  14.  
  15. Be sure to tape the shaft splines before installing the boots. Fill the inside of the boot with the specified grease and install the boot on the halfshaft.
  16.  
  17. Install a new stop ring, if needed.
    NOTE
    The circlip must not be re-used. A new circlip must be installed each time the outboard CV-joint is installed on the halfshaft.

  18.  
  19. Install the new circlip on the halfshaft. Start one end in the groove and work the circlip over the shaft end into the groove. This will avoid over-expanding the circlip.
  20.  
  21. Position the CV-joint on the halfshaft, carefully aligning the CV-joint splines with the halfshaft splines.
  22.  
  23. Using a brass hammer or mallet, tap the CV-joint until the circlip locks into the inner race. The joint should not be able to be pulled from the halfshaft by hand if the circlip is seated.
  24.  
  25. Install the boot and tighten the boot bands securely. Make sure the distance between the boot bands is correct.
  26.  
  27. Install the halfshaft in the vehicle.
  28.  

 
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