Hi again. In this thread you folks helped me diagnose my scuffing sound to a probably failing U-Joint. Thanks again.
I’ve pulled out my handy-dandy Haynes guide and it talks about remove the U-joint from the drive shaft in great detail. (Remove snap rings, use a bench vise to press out the pegs, removing the bearing caps as each is pushed clear of the yoke.)
It’s really light, though, on inserting the new one. Look at my U-joint, it looks like i’d be trying to stuff a 3-inch “star” into a 2.5-inch gap.
Your have to put in one bearing cap, greasing it thoroughly so the needles don’t fall out. Then feed the cross into that bearing and then push the other bearing in being very carefull to line it up so the boss on the star slips into the bearing. Again, grease the cap heavily to avoid losing the needles.
When you put the first bearing cap in don’t push it in any further than needed to get the snap ring well seated in the groove, otherwise the joint will be a little tight.
First off make sure that your drive shaft has replaceable u-joints. Many Japanese cars and trucks don’t.
There must be snap rings on the ends of the cups. If you don’t see snap rings but just a staked part of the metal, it is not a DIY project.
Next please understand that changing U joints is not allways easy. If fact most times it is damn hard bording on impossible. This is coming from a guy that did this stuff for a living. I hate u joints.
Still game? Sucker.
OK you will need
Rust penetrant (PB Blaster is a very good brand)
Internal snap pliers
a BFH* with a soft face (Copper or lead or plastic)
A large bench vice
Some emery cloth
A 1/2 round file
Two sockets that are just smaller than the cups on the joint.
A large brass punch.
Medium to large slip joint pliers (AKA channel locks or water pump pliers)
Procedure:
The night before spray the joint with rust penetrant
Remove shaft
remove snap rings (all 4)
Spray some additional rust penetrant on the cups.
Open the vice till the yoke (the part that is shapped like a Y) part of the joint is supported on both sides but is clear n the bottom.
Lay the shaft so that the shaft side yoke is supported and the flange side yoke is vertical.
Rap the flange smartly with your soft faced BFH. Continue to rap. Rap the shit out of it until the cup is about 1/4" or so above the yoke.
Turn the shaft 180 degrees. Lather. rinse, repeat.
Lightly close the vice on the shaft and using the slip joint pliers remove the two cups.
remove the flange.
Support the two side of the cross joint on the jaws of the vice and rap the shaft right at the junction of the yoke to release that cup. Turn the shaft 180 and repeat.
Remove those two cups.
Clean the holes in the yokes with the emery cloth, and if there are any dings on the inner edge use the file to dress them Clean everything off so that none of the crap from the file or emery cloth gets in the new joint.
Take the new joint and look at it closely, some only go in one way. You do not want to have to do this job over. If there is a grease fitting on the new joint, it will probably face the shaft.
Take the cups off the new joint. Add just a touch of grease to hold the needels in place. If you add too much the joint will hydrolock and you won’t be able to get the clips in. Too little and the needles will fall out.
Anyway place the cross in the shaft yoke, and place the cups in from the outside. Hold the cups in place with one hand, and use your second hand adjust the vice so that is is open far enough to admit the joint and as soon as it is in place you can close it to hold the cups in place. Using your third hand place the shaft in place. (I told you it was fun)
Making sure that you are holding the shaft square (Perpendictular to the closing of the vice) slowly close the vice ensuring that the cross part of the joint enters both cups. continue to squeese until the cups are as far in as possible. Open the vice and add sockets and suqeese until the cups will no longer move inward. If you are the luckiest guy alive you can now put in both snap rings.** More likely is one will go in, the other won’t. Put in the snap ring that will fit. Place the snap ring end down on the bench or floor, and place the socket on the other side. Rap with your hammer until you can insert the other snap ring. Make sure both snap rings are fully seated. Double check.
The flange end is an exact repeat of what you just did.
When you are all done, rotate the joint by hand, if it is stiff place it back in the vice as if you were taking it all apart again (Leave the snap rings in!) Rap with a hammer, rotate 90 degrees rap. Do all 4 sides. The joint should now feel free. If not repeat.
A Big Fucking Hammer
** If this happens, stop work and go buy a lottery ticket.