Replace the outer CV boot on a 2015-2020 Ford F-150 3.5L EcoBoost RWD to prevent axle contamination and failure.

Warnings

Tools required

Parts

• Outer CV boot kit with clamps and grease × 1 — Use OEM specification
• Axle nut (if staked type) × 1 — Use OEM specification
• Cotter pin (if applicable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock the rear wheels securely
3. Loosen wheel lug nuts while vehicle is on the ground
4. Raise front of vehicle and support on jack stands at frame contact points
5. Remove front wheel on affected side

Procedure

1. 1

   Remove axle nut
   With vehicle still supported on jack stands and parking brake engaged, use a breaker bar to remove the axle nut. If the nut is staked, you may need to use a chisel to unstake it first. Discard the old nut if it is a staked type as it cannot be reused.
2. 2

   Support lower control arm
   Place a jack under the lower control arm to support the suspension at ride height. This prevents stress on suspension components and maintains proper working angles during CV boot service.
3. 3

   Remove outer tie rod end
   Remove the cotter pin and castle nut from the outer tie rod end. Use a tie rod separator or pickle fork to separate the tie rod end from the steering knuckle. This provides clearance to work on the outer CV joint.
4. 4

   Mark CV joint orientation
   Before disassembly, use a paint marker to mark the relationship between the CV joint housing and the axle shaft. This ensures proper reassembly alignment and prevents potential vibration issues.
5. 5

   Remove old boot clamps
   Use side cutters or boot clamp pliers to cut and remove both clamps securing the outer CV boot. Note the position of the clamps for reinstallation reference. Slide the old boot away from the CV joint toward the center of the axle.
6. 6

   Clean CV joint and inspect
   Wipe away the old grease from the outer CV joint using shop rags. Inspect the joint for wear, pitting, or damage to the balls and races. Check for any clicking or binding when rotating the joint. If damage is found, the entire axle assembly should be replaced rather than just the boot.
   ℹ️If the CV joint shows any wear or damage, replacing only the boot is not recommended as joint failure will occur shortly
7. 7

   Remove CV joint from shaft
   Pull the outer CV joint housing straight off the axle shaft. The joint is typically retained by a snap ring or circlip on the shaft. Note the position and orientation for reassembly. Clean the axle shaft splines thoroughly with brake cleaner.
8. 8

   Remove old boot completely
   Slide the old boot completely off the axle shaft. Inspect the shaft for any damage, corrosion, or wear. Clean the entire shaft area where the new boot will sit using brake cleaner and allow to dry.
9. 9

   Install new boot and clamps
   Slide the new boot onto the axle shaft along with both new clamps (do not tighten yet). Ensure the boot is positioned in the same location as the original. The smaller end of the boot faces the transmission side.
10. 10

    Reinstall CV joint with new grease
    Pack the CV joint housing with approximately half of the supplied grease from the boot kit. Align the marks made earlier and reinstall the CV joint onto the axle shaft, ensuring the snap ring fully seats. Pack the remaining grease into the boot cavity around the joint.
11. 11

    Position and secure boot
    Position the boot over the CV joint, ensuring it sits properly in both the shaft groove and the joint housing groove. Burp the boot by carefully lifting the edge to release any trapped air. Install and tighten both clamps using the CV boot clamp tool, ensuring they are secure and properly seated in the boot grooves.
12. 12

    Reinstall tie rod end
    Reinstall the outer tie rod end into the steering knuckle. Install the castle nut and tighten to specification, then install a new cotter pin. Ensure the cotter pin is properly spread to prevent loosening.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Install axle nut
    Install a new axle nut (if staked type) onto the axle shaft. With the vehicle still on jack stands and parking brake engaged, torque the axle nut to specification. If using a staked nut, use a punch and hammer to stake the nut collar into the axle shaft groove. If using a cotter pin type, align the castle nut slots and install a new cotter pin.
    ⚠Axle nut must be torqued with vehicle weight off the ground but hub secured from rotation
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
14. 14

    Reinstall wheel and lower vehicle
    Reinstall the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle to the ground and torque the lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify the CV boot is properly seated with no air pockets or twisting
3. Check that the axle nut is properly staked or has a new cotter pin installed
4. Confirm the tie rod end is secure and steering moves freely

Verification

• Test drive the vehicle and listen for any clicking or popping noises during turns, which would indicate CV joint issues
• Inspect the new boot for any leaks or grease seepage after the test drive
• Turn the steering wheel full lock in both directions while moving slowly to verify proper operation
• Visually inspect the boot after 100 miles of driving to ensure clamps remain tight and no grease is leaking

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