This procedure covers the replacement of the inner CV boot on a 2011-2014 Ford F-150 with 5.0L V8 4WD, requiring removal of the front halfshaft and disassembly of the inner CV joint.

Warnings

Tools required

Parts

• Inner CV boot kit with clamps and grease × 1 — Use OEM or Dorman 614-101 equivalent
• Front differential fluid gasket or RTV sealant × 1 — Motorcraft TA-357 or equivalent
• New axle nut cotter pin or stake washer × 1 — Per vehicle specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground (do not remove)
3. Raise front of vehicle and secure on jack stands rated for vehicle weight
4. Remove front wheel on side being serviced
5. Place drain pan under front differential on side being worked on

Procedure

1. 1

   Remove axle nut
   Remove and discard the cotter pin or unstake the axle nut. Use a breaker bar to remove the 30mm or 35mm axle nut from the end of the halfshaft while an assistant applies the brakes or use a pry bar to prevent hub rotation. Keep the nut for torque reference but plan to use proper staking method or new cotter pin on reassembly.
2. 2

   Disconnect inner CV joint from differential
   Locate the six CV bolts connecting the inner CV joint flange to the front differential output flange. These are accessible from behind the halfshaft. Remove all six bolts and carefully support the halfshaft. Some differential fluid will begin to drain at this point.
   Torque spec

   CV Bolts76 Nm (56 lb-ft)
3. 3

   Remove halfshaft assembly
   Pull the outer end of the halfshaft outward from the wheel hub while supporting the inner end. The splined shaft should slide out of the hub. You may need to tap the end with a rubber mallet or use a small puller if stuck. Completely remove the halfshaft from the vehicle and place on clean work surface. Allow remaining differential fluid to drain into pan.
4. 4

   Remove inner CV boot clamps
   Use CV boot clamp pliers or side cutters to remove both the large and small clamps securing the inner CV boot. The small clamp is near the shaft, the large clamp is at the CV joint housing. Slide the boot away from the CV joint toward the center of the shaft to expose the joint mechanism.
   ⚠Cut clamps carefully to avoid damaging the shaft surface or outer CV boot.
5. 5

   Mark and disassemble CV joint
   Before disassembly, use a paint marker or scribe to mark the relationship between the tripod housing, tripod spider, and shaft. Remove the snap ring or retaining clip that holds the tripod assembly to the shaft using snap ring pliers. Slide the tripod housing off, then carefully slide the tripod spider assembly off the shaft. Note the orientation of the tripod spider relative to the shaft splines.
   ℹ️The tripod rollers may fall off when removing the spider assembly. Keep track of all needle bearings and rollers.
6. 6

   Remove old boot and clean components
   Slide the old inner CV boot completely off the shaft. Thoroughly clean the shaft, tripod spider, housing, and all CV joint components using brake cleaner and a wire brush. Remove all old grease. Inspect the tripod rollers, spider bearing surfaces, and housing tracks for wear, pitting, or damage. Replace the entire joint if excessive wear is present.
7. 7

   Install new boot and prepare assembly
   Slide the new small clamp onto the shaft, then slide the new CV boot onto the shaft with the small end toward the center of the shaft. Position the small end of the boot in the boot groove on the shaft but do not clamp yet. Ensure the boot is not twisted.
8. 8

   Reinstall tripod assembly
   Pack the tripod spider and rollers with the CV grease supplied in the boot kit (typically 2-3 oz). Slide the tripod spider back onto the shaft in the same orientation as marked during disassembly, aligning the splines. Install the snap ring or retaining clip to secure the tripod to the shaft. Verify the snap ring is fully seated in its groove.
9. 9

   Pack housing and install boot
   Place the remaining CV grease from the kit into the tripod housing (typically 3-4 oz total grease in joint). Slide the housing over the tripod assembly, aligning the marks made during disassembly. Work the housing back and forth to distribute grease evenly. Slide the large end of the boot over the housing and seat it in the boot groove on the housing.
10. 10

    Install boot clamps and equalize pressure
    Before clamping, compress and extend the CV joint several times to distribute grease, then set the joint at mid-travel position. Lift the boot edge slightly to burp any trapped air. Install and tighten the small clamp at the shaft end using CV boot clamp pliers, ensuring it is tight and properly crimped. Install and tighten the large clamp at the housing end in the same manner. Verify both clamps are secure and the boot is not twisted or kinked.
11. 11

    Reinstall halfshaft assembly
    Clean the differential output flange and the CV joint flange mating surfaces. Guide the outer end of the halfshaft back into the wheel hub, pushing until the splines engage. Align the inner CV joint flange with the differential output flange. Insert all six CV bolts and tighten in a star pattern to proper torque specification.
    ℹ️Ensure the halfshaft is fully seated in the hub before proceeding to avoid misalignment.
    Torque spec

    CV Bolts76 Nm (56 lb-ft)
12. 12

    Install and torque axle nut
    Install the axle nut onto the end of the halfshaft. Have an assistant apply the brakes or use a pry bar to prevent rotation. Torque the axle nut to specification. Install a new cotter pin through the castle nut and bend the ends, or properly stake the nut washer per Ford specification.
    ⚠Never reuse the old cotter pin or rely on an unstaked nut. Axle nut loosening can cause catastrophic failure.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
13. 13

    Refill front differential
    Locate the front differential fill plug (usually on the front or side of the housing). Remove the fill plug and add 75W-90 GL-5 gear oil until it reaches the bottom of the fill hole (approximately 1.5 quarts). Reinstall and tighten the fill plug. Check for leaks around the differential output flange.
14. 14

    Reinstall wheel and lower vehicle
    Reinstall the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground. Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all CV boot clamps are properly tightened and secured to prevent boot rotation or grease leakage
2. Verify the axle nut is properly torqued and secured with a new cotter pin or properly staked
3. Double-check that all six CV bolts are torqued to specification in a star pattern
4. Confirm front differential is filled to proper level and fill plug is tight

Verification

• Start the engine and turn the steering wheel full left and full right while stationary to check for binding or noise
• Test drive the vehicle at low speed, making several turns in both directions while listening for clicking, popping, or vibration from the CV joint
• After test drive, inspect the new CV boot for any signs of grease leakage or boot movement on the shaft or housing
• Check the differential fill plug area and output flange for any fluid leaks
• Re-check wheel lug nut torque after 50-100 miles of driving

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