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U-Joint Replacement
 

We now need to repeat the bearing cap install process, this time using the inner axle shaft.  In the above picture, I have positioned the cross into the yoke ears of the inner shaft.  I have also started one of the two remaining bearing caps into the yoke ear.
 

Once again, properly position the screw of the u-joint press on the center of the bearing cap and apply pressure.  The cap will push into the yoke ear just as it did before.
 

After the cap is pushed into place (remember, I push mine just a bit further than the need to be), take a new C clip and install it in the groove on the bearing cap.  Make sure the C clip fits properly in the groove.  You don't want to loose one of these on the trail, as it can cause the bearing cap to become loose and if this happens, the u-joint will surely fail.  After the clip is in place, install the remaining bearing cap and then install its C clip as well.  As this point, you will have a fully assembled u-joint.
 

The u-joint I used (Napa 377 Extra Strength) comes with a screw in needle grease fitting.  It is screwed into place with a flat blade screwdriver.  Some folks don't like greasable u-joints while others do.  Me?  Well, I am still trying to figure out which one is best.  For now, I am pretty sure that these trail spare axle shafts will get me off of the trail before the u-joint fails because of a grease channel.
 

OK....that is all there is to it.  Here is one completely overhauled u-joint.  
 

From here, they get wrapped in that heavy duty shipping wrap (that industrial strength Saran Wrap) and put in the Jeep.  With luck, I'll never use them.  But, if I do manage to take out a u-joint, I know I have a properly assembled spare shaft that will do the job.  And hey....don't forget to get yourself one of those handy Harbor Freight u-joint presses.  I tell you, they make this kind of job so easy to do!

 

 

 

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