This procedure covers the replacement of the outer CV boot on a 2021-2024 Ford F-150 3.5L EcoBoost RWD, requiring removal of the wheel, axle components, and CV joint from the differential.

Warnings

Tools required

Parts

• Outer CV boot kit with grease and clamps × 1 — Use OEM specification or quality aftermarket equivalent
• Axle nut (new) × 1 — Use OEM specification if staked type
• New cotter pin or stake hardware × 1 — Check axle nut type

Preparation

1. Park vehicle on level ground and engage parking brake
2. Chock rear wheels securely
3. Loosen axle nut approximately 1/4 turn while vehicle is still on ground (do not remove)
4. Loosen wheel lug nuts 1/4 turn while vehicle is on ground
5. Lift front of vehicle and secure on appropriate jack stands rated for vehicle weight
6. Remove wheel completely
7. Place drain pan under work area to catch any differential fluid seepage

Procedure

1. 1

   Remove axle nut and disconnect CV joint from differential
   Fully remove the axle nut that was previously loosened. Mark the relationship between the CV joint and differential flange with paint or marker for proper reassembly alignment. Remove the CV joint bolts connecting the inner CV joint to the differential flange. Use a pry bar if needed to separate the joint from the differential. Support the halfshaft to prevent damage.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)

   CV Joint Bolts71 Nm (52 lb-ft)
2. 2

   Remove halfshaft assembly from vehicle
   Carefully pull the halfshaft outboard through the hub assembly. You may need to use a soft mallet to tap the shaft from behind if it is stuck in the hub splines. Support the shaft and place on a clean work surface. Inspect the hub bearing and splines for damage or excessive wear.
3. 3

   Remove old outer CV boot clamps
   Cut or remove both clamps securing the outer CV boot (large clamp near joint, small clamp near shaft). Use CV boot clamp pliers or side cutters. Slide the old boot away from the CV joint toward the center of the shaft. If the boot is stuck, carefully cut it away but avoid damaging the shaft surface.
4. 4

   Clean and inspect CV joint
   Wipe away all old grease from the outer CV joint, shaft, and boot seating areas using clean rags. Inspect the joint for wear, pitting, or damage on ball bearings and races. Rotate the joint through its full range of motion checking for roughness, clicking, or binding. If any damage is found, replace the entire halfshaft assembly rather than just the boot. Clean the shaft surface where the new boot will sit with solvent and dry thoroughly.
   ℹ️A torn boot often allows contamination that damages the CV joint. Carefully inspect for early-stage damage.
5. 5

   Install new outer CV boot (dry fit)
   Slide the small clamp onto the shaft first, followed by the new CV boot with the small end toward the shaft center. Position the small end of the boot in the groove on the shaft. Do not clamp yet. Ensure the boot is not twisted and is properly seated in the shaft groove.
6. 6

   Pack CV joint with grease
   Pack the CV joint with the grease supplied in the boot kit. Work grease into all ball bearings and races by hand, rotating the joint. Use the full amount of grease provided (typically 150-200 grams). Also place grease inside the boot cavity. The joint and boot should be generously packed but not overfilled to the point of bursting.
7. 7

   Seat boot and install clamps
   Slide the large end of the boot over the CV joint housing and seat it in the joint's boot groove. Ensure the boot is not twisted and both ends are fully seated in their grooves. Relieve any air pressure by carefully lifting the boot edge. Install the small clamp on the shaft end and tighten securely using CV boot clamp pliers. Install the large clamp on the joint end and tighten securely. Both clamps must be tight enough to prevent grease leakage and water intrusion.
8. 8

   Reinstall halfshaft assembly
   Clean the hub splines with a wire brush. Carefully guide the halfshaft back through the hub assembly, ensuring the splines engage properly. Do not damage ABS sensor components near the hub. Thread on the new axle nut by hand but do not torque yet. Support the inner CV joint end.
9. 9

   Reconnect CV joint to differential
   Align the inner CV joint to the differential flange using the alignment marks made during disassembly. Install the CV joint bolts and tighten in a star pattern to ensure even seating. Torque the CV joint bolts to specification. Ensure the joint is fully seated against the flange.
   Torque spec

   CV Joint Bolts71 Nm (52 lb-ft)
10. 10

    Reinstall wheel and torque axle nut
    Reinstall the wheel and thread lug nuts by hand. Lower the vehicle until the tire just touches the ground (weight still on jack stands). Torque the axle nut to specification using a breaker bar and torque wrench. Install new cotter pin or stake the nut as required by the axle nut design. Fully lower the vehicle and torque wheel lug nuts in a star pattern to specification.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all CV joint bolts are torqued to specification in a star pattern
2. Verify axle nut is properly torqued and secured with new cotter pin or staking
3. Check that CV boot clamps are tight and boot is not twisted or kinked
4. Verify no tools or parts are left in wheel well area
5. Check differential fluid level if significant seepage occurred during service

Verification

• Start engine and turn steering wheel lock-to-lock while stationary to verify no clicking or binding
• Test drive vehicle at low speed and verify no vibration, noise, or clicking from the CV joint area during acceleration, deceleration, and turning
• After test drive, visually inspect the new boot for proper seating, secure clamps, and no grease leakage
• Re-check axle nut torque after 50-100 miles of driving

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