Section 05-01: Driveshaft
1996 F-150, F-250, F-350 4x2, 4x4, F-Super Duty Chassis Cab, Motorhome Chassis and Bronco Vehicles Workshop Manual
DISASSEMBLY AND ASSEMBLY

Slip Between Center Driveshaft

 

Slip Between Center Driveshaft





ItemPart NumberDescription
14635Universal Joint Kit
2—Bearing (Part of 4635)
3—Snap Ring (Part of 4635)
4—Seal (Part of 4635)
5—Spider (Part of 4635)
6—Splined Stub Shaft
(Part of 4602)
74421Slip Yoke Boot
84841Driveshaft Slip Yoke
9—Boot Groove (Part of 4841)
104K227Large Clamp
114K227Small Clamp
124602Driveshaft
13—Front Driveshaft Yoke
(Part of 4602)


SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Keystone Clamp PliersT63P-9171-A

Disassembly

  1. With the front driveshaft on a bench, cut the driveshaft slip yoke boot clamps (4K227) with sidecutters. Remove and discard the clamps.





  1. Separate the driveshaft slip yoke (4841) from the splined stub shaft on the driveshaft.

  1. Remove the slip yoke boot. Inspect the slip yoke boot for rips or holes and replace if required.

  1. If, during inspection, the driveshaft and coupling shaft boot is found to be cracked or split, the grease should be checked for contamination. Check the lubricant by rubbing between two fingers. Any gritty feeling indicates a contaminated driveshaft slip yoke and stub shaft. If driveshaft (4602) is operating satisfactorily and the grease does not appear to be contaminated, add grease as described in the assembly portion of this procedure and replace the slip yoke boot. If the grease appears contaminated, disassemble the driveshaft, clean and inspect the stub shaft and driveshaft slip yoke for wear. If splines are excessively worn, replace driveshaft.

  1. If required, remove and replace the U-joints.

Assembly

  1. Install the slip yoke boot with the small diameter side facing the splined stub shaft on the stub shaft. Push the slip yoke boot as far as it will travel on the stub shaft.





  1. Install a small driveshaft slip yoke boot clamp and crimp the clamp using Keystone Clamp Pliers T63P-9171-A.





  1. Compress the slip yoke boot and coat the stub shaft splines with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.

  1. Fill the slip yoke boot with approximately 10 grams of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.

  1. Slide the large driveshaft slip yoke boot clamp onto the barrel of the driveshaft slip yoke.

  1. Align the blind splines on the splined stub shaft and in the driveshaft slip yoke. Push the driveshaft slip yoke onto the stub shaft.





  1. Remove all excess grease from the slip yoke boot and driveshaft slip yoke surfaces. Position the slip yoke boot over the driveshaft slip yoke boot groove.

  1. Move the driveshaft slip yoke in or out in order to obtain the distance of 10 inches between stud shaft weld to the centerline of the driveshaft slip yoke U-joint.





  1. Before installing the new large slip yoke boot clamp, make sure that any air pressure which may have built up in the slip yoke boot is relieved. Carefully insert a screwdriver between the slip yoke boot and the driveshaft slip yoke and allow the trapped air to escape ("burp") from the slip yoke boot. THE AIR MUST BE RELEASED ONLY AFTER THE DRIVESHAFT IS SET AT THE SPECIFIED LENGTH.





  1. Position the new large driveshaft slip yoke boot clamp over the slip yoke boot and groove in the driveshaft slip yoke. Crimp the driveshaft slip yoke boot clamp with Keystone Clamp Pliers T63P-9171-A.