Tools you'll likely need:
* Jack and jack stands: Essential for safely lifting the vehicle.
* Wheel chocks: Crucial for safety.
* Lug wrench: To remove the wheel.
* Socket set and wrenches: Various sizes will be needed.
* Ball joint separator (pickle fork or similar): To separate the ball joint from the control arm (likely needed for outer CV joint).
* CV joint removal tool: Makes removing the joint from the axle shaft much easier. A slide hammer can also work.
* Penetrating oil (PB Blaster or similar): Helps loosen rusted or seized bolts and components.
* Torque wrench: To tighten bolts to the manufacturer's specifications.
* New CV joint: Ensure you get the correct one for your vehicle.
* Grease: For packing the new CV joint.
* Hammer and punch (possibly): May be needed to help separate components.
* Safety glasses and gloves: Protect yourself.
General Steps (Outer CV Joint - More Common Replacement):
1. Safety First: Park on a level surface, engage the parking brake, and use wheel chocks.
2. Lift and Support: Safely lift the vehicle and secure it on jack stands.
3. Remove Wheel: Remove the wheel.
4. Disconnect Brake Caliper: Carefully remove the brake caliper and hang it out of the way. Support the caliper with wire to prevent damage to the brake line.
5. Disconnect Sway Bar Link (If Necessary): This might need to be disconnected depending on access.
6. Separate Ball Joint: Use a ball joint separator to separate the lower ball joint from the control arm. This is often the most difficult part. Be careful not to damage the ball joint boot or control arm.
7. Remove Axle Nut: Remove the large axle nut securing the axle to the wheel hub.
8. Separate Axle from Hub: Separate the axle from the wheel hub.
9. Remove Outer CV Joint: This requires a CV joint removal tool or a slide hammer. This is where the right tools are essential to prevent damage to the axle.
10. Install New CV Joint: Pack the new CV joint with grease and install it onto the axle shaft using the appropriate tool.
11. Reassembly: Reassemble everything in the reverse order of disassembly, ensuring all components are properly seated and tightened to the correct torque specifications. Pay close attention to the ball joint, making sure it's properly seated and secured.
12. Lower Vehicle: Carefully lower the vehicle from the jack stands.
13. Test Drive: Test drive the vehicle to ensure the repair was successful.
Inner CV Joint Replacement:
Replacing the inner CV joint is more involved, often requiring dropping the driveshaft or at least partially removing it from the transmission. This is significantly more difficult and requires more specialized tools and knowledge. Unless you are very experienced, this is best left to a professional.
Important Considerations:
* Drive Axles: The Villager uses half-shafts, meaning the CV joint is integral to the axle. You're replacing the entire axle shaft assembly, not just the CV joint itself.
* Boot Condition: Inspect the CV joint boot carefully. If it's torn, it needs replacement, even if the joint itself seems fine. A torn boot allows dirt and contaminants to enter the joint, quickly leading to failure.
* Professional Help: If you're not comfortable with this repair, take it to a qualified mechanic. Improperly replacing a CV joint can lead to serious damage and safety hazards.
This information is for guidance only. Always refer to a repair manual specific to your 1999 Mercury Villager for detailed instructions and torque specifications. Improper repair can result in damage to your vehicle and potential injury.
