Universal joints — replacement
Note: Always purchase a universal joint service kit for your model vehicle before beginning this procedure. Also, read through the entire procedure before beginning work.
1. Remove the driveshaft (see Driveshaft(s) — removal and installation).
Outer snap-ring type
2. Place the driveshaft on a bench equipped with a vise.
3. Remove the snap-rings with a small pair of pliers (see illustration).
5.3 Use a small pair of pliers to remove the snap-rings from the ends of the universal joint yokes
4. Place a piece of pipe or a large socket, having an outside diameter slightly larger than the outside diameter of one of the bearing caps, over one of the bearing caps. Position a socket with an outside diameter slightly smaller than that of the opposite bearing cap against the cap (see illustration) and use the vise or press to force the bearing cap out (inside the pipe or large socket).
5.4 To remove the U-joint from the driveshaft, use a vise as a press — the small socket will push the U-joint and bearing cap into the large socket
5. Press the U-joint through as far as possible, then grip the bearing cap with pliers and remove it (see illustration).
5.5 Locking pliers can be used to remove the bearing caps from the yoke
6. A universal joint repair kit will contain a new U-joint, seals, bearings, caps and snap-rings (see illustration).
5.6 Outer snap-ring type U-joint
7. Inspect the bearing cap bores in the yokes for wear and damage.
8. If the bearing cap bores in the yoke are so worn that the caps are a loose fit, the driveshaft will have to be replaced with a new one.
9. Make sure the dust seals are properly located on the U-joint.
10. Using a vise, press one bearing cap into the yoke approximately 1/4-inch.
11. Use chassis grease to hold the needle rollers in place in the caps.
12. Insert the U-joint into the partially installed bearing cap, taking care not to dis- lodge the needle rollers.
13. Hold the U-joint in correct alignment and press both caps into place by slowly and carefully closing the jaws of the vise.
14. Use a socket slightly smaller in diameter than the caps to press them into the yoke. Press in one side, install the snap-ring, then press the other side to shift the U-joint assembly tight against the installed snap-ring and install the other snap-ring.
15. Repeat the operations for the remaining two bearing caps. Proceed to Step 22.
injected plastic (inner snap-ring) type
16. If the joint has been previously rebuilt, remove the snap-rings (bearing retainers) located on the inner part of each bearing cap (see illustration).
5.16 Remove the inner snap-rings from the U-joint by tapping them off with a screwdriver and hammer
17. If this is the first time the joint is being rebuilt, it will not be necessary to remove the snap-rings, since there aren’t any; the pressing operation will shear the molded plastic retaining material.
Note: It may be necessary to heat the U-joint over 500-degrees (melting the plastic retaining material) before pressing the U-joint apart.
18. Press out the bearing caps as described in Steps 4 and 5.
19. Remove the U-joint and clean all plastic material from the yoke. Use a small punch to remove the plastic from the injection holes.
20. Reassembly is the same as for the outer snap-ring joint described in Steps 9 through 15, except the snap-rings are on the inner part of each bearing cap (see illustration).
5.20 Inner snap-ring type U-joint
21. When installing the bearing cap, press it in until the snap-ring can be installed (see illustration).
5.21 Installing a snap-ring on an inner snap-ring type U-joint
All models
22. If the joint is stiff after assembly, strike the yoke sharply with a hammer (see illustration). This will spring the yoke ears slightly and free up the joint.
5.22 Strike the yoke sharply with a hammer to spring the yoke ears, which will free-up the joint
