!Guide! Inner & Outer CV Boots/Bearing Replacement MK7 2011

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-Ford Fiesta Zetec JA8  08-13

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Misc:
-Check all 4 boots for any deterioration or clicking from any joint
-Suspension nuts/bolts should IDEALLY be replaced
-Replace the joint/bearings if the joint is clicking or if the boot has been torn for a while

-This guide is for fully removing the driveshaft(s) then replacing either the inner boot and/or the inner bearing. It is also for additionally replacing the outer boot and/or joint. Although the outer section of the repair can be ignored if it is not warranted. 
-If you wish to only replace the outer CV boot and/or joint then the driveshaft does not need to be removed from the car (Refer to the stand alone guide)

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-Crack off the wheel which accompanies the driveshaft(s) that needs to be repaired (19mm)4
-Put the relevant corners on axle stands
-Remove any relevant wheels (19mm)

-Spray penetrating oil into the threads of the hub nut(s), wishbone bolt(s), track rod end nut(s)

-Remove the 30mm hub nut with an impact gun or breaker bar

-Back off the track rod end nut with an impact gun until it starts to spin in the joint
-Clean out the head of the hex key ball joint stud
-Remove the 19mm nut (spanner) that secures the track rod end(s) to the steering knuckle(s) (Hold the ball stud with a 5mm hex key)
(If the hex key ball stud rounds off then lift the ball joint up with a jack to prevent it from turning & then take the nut off with an impact gun)
-Tap the steering knuckle with a hammer until the track rod end(s) falls free from its mounting point 

-Remove the 15mm bolt that secures the wishbone ball joint(s) to the steering knuckle(s) (Fastened with 13mm nut - hold with a spanner)
-Tap the bolt(s) out with a centre punch
-Pry the steering knuckle(s) away from the wishbone ball joint

-Spray penetrating oil into the splines of the outer shaft(s)
-Pull the steering knuckle outwards and then hammer the driveshaft(s) out of situ using a drift chisel in the divot on the shaft (Alternatively overhang the hub nut over the threads on the shaft(s) to protect the threads & then hit that - IF YOU ARE REPLACING THE HUB NUT(S)
-Turn the steering knuckle to one side and then release the driveshaft(s)

-Turn the driveshaft(s) by hand until you can see the metal crimp securing the inner CV joint to the cup
-Cut the crimped section of the band and then pull the driveshaft(s) out from the cup
-Clean any excess grease from the outside of the cup(s)

-Clamp the driveshaft(s) into a vice with the (inner joints) spider facing up
-Clean the grease from the top of the spider(s)
-Wedge a large flathead screwdriver between the opening of the clip(s) that is securing the spider(s) in place
-Wedge a small flathead screwdriver in the gap behind the clip(s) & pry the clip off
-Remove the spider(s) and fully clean the grease from the bearings (If you are not replacing it)
-If the spider is seized on then spray it with penetrating oil & pull it off with a bearing puller tool
-If this does work then bray it off with a 1kg hammer and a BLUNT chisel on each side of the inner bearing race 
-If you are not replacing the spider(s) then mark the top of the spider(s) with pen or Tipp-Ex so that you orient it the correct way on reassembly  
-Make a mark on the shaft(s) where the end of the boot needs to sit
-Cut the small retaining bands and discard the boot(s)
-Clean the grease from the end of the shaft(s)
-Wire brush the splines on the shaft(s) (Also on the inner race splines if you are not replacing the spider(s)

-Turn the shaft(s) around in the vice so that you have access to the outer joints
-Cut the large & small clips from the outer boot(s) and pull the boot(s) off the shaft(s)
-Wipe down the shaft again

(If you are only replacing the outer boot(s) & not the outer joint(s) then move on to the next section)
-If you are replacing the outer CV joint(s) then knock it off the shaft(s) with a hammer and chisel
-You can leave the snap ring on the end of the shaft as long as it doesn't prevent you from removing the boot. Ideally though, you should replace the snap ring.
-Clean up the splines
-Push the boot back onto the shaft(s) - With the small band in position
-Pack the new CV joint with driveshaft grease
-Align the splines with the driveshaft(s) and tap into place with a hammer until you hear a click
-Put the rest of the grease into the boot(s)
-Line up the boot(s) & then secure the large band in place by pulling tight & crimping
-Line up the small end of the boot(s) & then secure the small band(s) by pulling tight & crimping

(If you are only replacing the outer boot(s) & not the outer joint(s)
-Clean off some of the old grease from the joint & replace it with fresh grease
-Push the boot back onto the shaft(s) - With the small band in already in position
-Put a bit more grease into the boot(s)
-Line up the boot(s) & then secure the large band in place by pulling tight & crimping
-Line up the small end of the boot(s) & then secure the small band by pulling tight & crimping

-Turn the shaft(s) around in the vice so that you have access to the inner shaft
-Push the boot back onto the shaft(s)
-Line up the small end of the boot(s) in position & then secure the small band(s) by pulling tight & crimping
-Put the new/old spider back onto the shaft(s) - Make sure that the spider(s) is oriented the correct way up - Make sure that the bearings line up with the grooves in the boot(s)
-If the spider(s) wont go back on then tap it on with a hammer and an appropriate sized socket
-Reinstall the snap ring to the end of the shaft(s), although ideally you should replace the snap ring
-Work a small amount of driveshaft grease into the needle bearings

-Squeeze grease into the driveshaft cup(s)
-Push the spider into the cup(s)
-Align the splines with the wheel hub and feed the driveshaft(s) in
-Tap the wheel hub(s) until the splines seat properly
-Push the suspension arm down then slide & hammer the ball joint into the steering knuckle(s)
-Torque the 15mm wishbone(s) nut to 52Nm (hold the bolt with a 13mm spanner) (Ideally replace the nut(s) & bolt(s)
-Secure the inner boot over the cup(s), line the boot up and crimp the large band

-Torque the 30mm wheel hub(s) nut to 255Nm (Ideally replace the nut)
-Torque the 19mm track rod end nut to 53Nm (Ideally replace the locking nut)
(Lift the ball joint up with a jack if it keeps spinning)

-Spray the brake disc(s) with brake cleaner
-Apply a conservative amount of aluminium anti seize to the hat of the rotor(s) (Don't get any on the studs)
-Put the wheel(s) back on (19mm)
-Wipe away any grease that is on the cup(s) or boot(s)
-Lower the car back down
-Torque all 19mm wheel nuts to 110Nm

-Go for a drive and make sure the car feels good
-Check the boot(s) one last time to make sure everything is secure

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Useful sources:

Ford Fiesta How To Do CV Boot Bodgit And Leggit Garage

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