This procedure covers replacement of the inner CV boot on a 2015-2020 Ford F-150 5.0L V8 RWD, which requires removing the driveshaft from the rear differential.

Warnings

Tools required

Parts

• Inner CV boot kit (includes boot, clamps, and grease) × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Motorcraft TA-22 or equivalent RTV

Fluids

• Motorcraft 75W-140 Synthetic Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels
3. Raise rear of vehicle and support securely on jack stands at frame rails
4. Allow differential to cool if vehicle was recently driven

Procedure

1. 1

   Mark driveshaft alignment
   Use marking paint or chalk to mark the alignment of the driveshaft yoke to the differential pinion flange. This ensures proper phasing during reassembly and prevents driveline vibration.
2. 2

   Remove driveshaft from differential
   Remove the four bolts securing the driveshaft universal joint straps to the differential pinion flange. Support the driveshaft and carefully slide it rearward to separate it from the differential. Lower the front of the driveshaft and rest it on the crossmember or suspend with wire to prevent damage.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
3. 3

   Drain differential fluid (optional but recommended)
   If desired for cleaner work area, place drain pan under differential cover. Remove the differential cover bolts in a crisscross pattern, starting from the top. Allow fluid to drain completely. Clean the cover and housing mating surfaces with wire brush and parts cleaner.
   ⚠Gear oil may be hot if vehicle was recently driven. Fluid will drain quickly once bottom bolts are loosened.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
4. 4

   Inspect CV joint and shaft
   With driveshaft accessible, inspect the inner CV joint for damage, excessive wear, or contamination. Check the shaft for straightness and surface damage. Clean the CV joint housing exterior with parts cleaner.
5. 5

   Remove old CV boot clamps
   Cut or release the old CV boot clamps on both the large (housing) and small (shaft) ends using appropriate clamp tool or side cutters. Slide the old boot away from the CV joint toward the center of the shaft.
6. 6

   Clean CV joint and shaft
   Wipe away old grease from the CV joint, housing, and shaft using clean rags and parts cleaner. Inspect the joint for wear, scoring, or damage. Check that the tripod bearings move freely without binding or excessive play. Do not disassemble the CV joint unless replacement is necessary.
7. 7

   Install new CV boot
   Slide the new boot onto the shaft from the center, positioning it over the CV joint area. Ensure the boot is not twisted and sits properly in the grooves on both the shaft and housing.
8. 8

   Pack CV joint with grease
   Apply the grease supplied in the boot kit into the CV joint housing, ensuring all bearing surfaces are completely coated. Use all grease provided in the kit - typically the entire packet. Work grease into the tripod bearings and around the housing interior.
9. 9

   Position and clamp boot
   Position the boot fully into the grooves on both ends. Install the small clamp on the shaft end first, ensuring proper tension. Then install the large clamp on the housing end. Ensure boot is not twisted and has proper amount of air inside - not over-inflated or collapsed. Tighten both clamps securely using the appropriate clamp tool.
10. 10

    Reinstall differential cover (if removed)
    If differential cover was removed, clean both mating surfaces thoroughly. Apply new gasket or RTV sealant as specified. Install cover and torque bolts in crisscross pattern to specification. Allow RTV to cure per manufacturer instructions before filling if applicable.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
11. 11

    Refill differential
    If drained, refill differential with Motorcraft 75W-140 Synthetic Gear Oil through the fill plug opening until fluid reaches the bottom of the fill hole. Install and tighten fill plug. Approximately 2 quarts capacity.
12. 12

    Reinstall driveshaft
    Align the marks made during removal to ensure proper phasing. Guide the driveshaft yoke onto the differential pinion flange. Install the universal joint strap bolts and torque evenly in a crisscross pattern to specification.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in the correct sequence
2. Verify driveshaft alignment marks match and there is no binding or interference
3. Check differential fluid level with vehicle on level ground
4. If RTV sealant was used on differential cover, wait appropriate cure time before driving

Verification

• Lower vehicle and test drive at various speeds to verify no vibration or noise from driveline
• Check for fluid leaks around differential cover and CV boot after test drive
• Inspect CV boot clamps to ensure they remain properly seated and tight
• Verify no grease leakage from boot after driving

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