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U-Joint Replacement
 

Insert the u-joint cross into the yoke and push a new bearing cap into the yoke ear.  Make sure you get everything lined up properly.  The cap should start a little way into the ear before meeting resistance, which makes it easy to get it started and then apply pressure using the u-joint tool.
 

One of the caps has been pressed completely into position.  Be sure to push the cap far enough into the ear so you can get to the C clip groove.  I found that I could push the cap in just a bit more than needed.  This made it very easy for me to install the C clip and ensure that it was fully seated in the groove.  The little bit of extra distance that the cap was inserted is automatically corrected when the opposite bearing cap is installed.
 

In the above picture, the left side bearing cap is already installed and I have started the right hand cap by hand.  The yoke is properly positioned in the u-joint tool and the screw will then be cranked down and push the right side cap into position.  You will be able to feel when the cap is completely seated as the tension on the clamp screw will quickly increase.  Check to make sure that the C clip that you installed on the left side has now been pushed back up against the yoke ear.  The C clip groove on the right bearing cap will now be clearly visible and you should have no problem inserting the clip.  After the clip is installed, release the tension on the clamp screw.  If you did a good job filling the grease channels in the cross, you should notice that some of the grease will have squeezed out of the two open ends of the cross while you were putting on the bearing caps.
 

Here is the outer axle shaft with the new u-joint properly installed.  Both C clips are in place.  Check the rotation of the u-joint.  It should move with slight resistance (mostly from that good quality grease you had pumped into the bearing caps.
 

More U-Joint Replacement

 

 

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