Tools Required

1. Remove the propeller shaft. Refer to Propeller Shaft Replacement .

Notice: Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal.

Notice: The flange yoke can be replaced without removing bearing cups from the tube yoke or ball support yoke.




2. Remove the bearing cups in the order indicated (1-4). This is the shortest route to the heart of the centering ball system. Make a close inspection in order to select the correct service method.



3. Mark all the yokes before disassembly in order to reassemble the yokes and in order to retain the driveshaft balance.
4. Support the propeller shaft in a line horizontal with the table of a press.
5. Remove the snap rings by pinching the ends together with a pair of pliers.
6. If the ring does not readily snap out of the groove in the yoke, tap the end of the bearing cup lightly in order to relieve the pressure from the ring.



7. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 in) socket.



8. In order to shear the plastic retaining ring on the bearing cup, place the J 9522-5 on the open horizontal bearing cups, and press the lower bearing cup out of the yoke ear.
9. If you have not completely removed the bearing cup, lift the cross and insert tool J 9522-5 between the seal and the bearing cup being removed and continue pressing the bearing cup out of the yoke.
10. Rotate the propeller shaft and press the opposite bearing cup out of the yoke.
11. Remove the cross from the center yoke.
12. Pull the centering socket yoke off the center stud.
13. Remove the rubber seal from the centering ball stud.
14. Remove the snap rings from the center yoke and from the propeller shaft yoke.
15. Press the remaining bearing assemblies out on the other cross as described above in order to complete disassembly.

Important: Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from being pressed into place or prevent the bearing retainers from being properly seated.

16. Clean all serviceable parts in cleaning solvent.
17. Clean the retaining ring grooves.

Notice: When a centering ball requires replacement, all ball seat components must be replaced also. A separate ball and seat service kit is available. The kit has two seat springs and the longer spring must be discarded.

18. Inspect the retaining ring grooves for dirt or corrosion.
19. Inspect the bearing cup bores for burrs or imperfections.
20. Inspect the socket yoke and the centering ball. If the centering ball surface shows signs of wear beyond a smooth polish, replace the centering ball.

1. Remove the bearing cups from the universal joint.
2. Coat the needle bearings in the bearing cup with a thin layer of chassis grease. Use your finger.



3. Position a cross into the tube yoke with one bearing cup part way into one side of the yoke.
4. Turn the yoke ear towards the bottom.
5. Install the cross into the yoke so that the trunnion seated in the bearing cup presses the bearing cup into the yoke until it is flush with the yoke ear.



6. Install the opposite bearing cup part way into the yoke ear.

•	Make sure that the trunnions are started straight and true into both bearing cups.

•	Press the opposite bearing cup into the yoke ear while working the cross all the time in order to check for free movement of the trunnions in the bearing cups.

Important: If the bearing cup starts to bind or hang-up, stop pressing and check the needle bearings for misalignment in the bearing cup.

•	Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup.

•	Install the snap ring in the retainer groove.

•	Continue pressing until both retainers are snapped into place.

•	If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead blow hammer.

•	It may be necessary to lubricate the snap ring with a slight amount of chassis grease so the snap ring seats in the bearing groove.

•	Pack the socket relief and the ball with chassis lubricant, then position the center yoke over the cross ends and press in the bearing.

•	Install the snap rings.

•	Install a new seal on the centering ball stud. Position the centering socket yoke on the stud making sure the spring in the tube yoke is in place.

•	Place the front cross in the center yoke. Make sure the cross bosses are properly positioned.

•	With the cross loosely positioned on the center stop, proceed to seat the first pair of bearings into the centering socket yoke, then press the second pair into the centering yoke.

•	Inspect for proper assembly. Flex the CV joint. The CV joint should snap over center to the right or left and up or down freely if assembled correctly.

7. Install the propeller shaft. Refer to Propeller Shaft Replacement .