Universal Joint Replacement Nylon Injected Ring Type

Tools Required

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.

1. Support the propeller shaft in a line horizontal with the table of a press.
2. Mark the propeller shaft in order to show which end connects to the transmission and which end connects to the rear axle.



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



4. In order to shear the plastic retaining ring on the bearing cup, place the J 9522-3 on the open horizontal bearing cups and press the lower bearing cup out of the yoke ear.
5. If the bearing cup is not completely removed, lift the cross, and insert the J 9522-5 between the seal and bearing cup being removed. Continue pressing the bearing cup out of the yoke.
6. Rotate the propeller shaft and press the opposite bearing cup out of the yoke.
7. Disassemble the cross from the yoke.




Important: Production universal joints cannot be reassembled. The production bearing cups do not have bearing retainer grooves. Discard all production universal joint parts you removed.

8. Remove the remaining universal joint parts from the yoke.
9. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner.
10. Inspect the retaining ring grooves for plastic.
11. Inspect the bearing cup bores for burrs or imperfections.
12. Clean the remains of the sheared plastic bearing retainers from the grooves in the yoke.

The sheared plastic may prevent proper seating of the new bearing cups.

1. Remove the bearing cups from the new universal joint journals.
2. Coat the needle bearings in the bearing cups with a thin layer of the grease that is present on the journal.
3. Apply the grease with your finger.



4. Install one bearing cup partway into one side of the yoke.
5. Turn the yoke ear towards the bottom.
6. Install the cross into the yoke so that the trunnion seats freely into the bearing cup.
7. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until it is flush with the yoke ear.



8. Install the opposite bearing cup partway into the yoke ear. Ensure that the trunnions are started straight and true into both bearing cups.
9. Press the opposite bearing cup into the yoke ear. Work the cross all of the time. Inspect for free unbinding movement of the trunnions in the bearing cups.
10. Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke.




Important: If a hangup or binding is evident , stop pressing. Inspect the needle bearings for misalignment in the bearing cup.

11. Install the bearing retainer in the retainer groove.

•	Continue pressing until both retainers snap into place.

•	A small amount of chassis grease may help the snap ring seat in the bearing cup groove.




12. If the retainer does not seat, spring the yoke slightly with a firm blow from a dead blow hammer.

Universal Joint Replacement External Snap Ring Type

Tools Required

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.

1. Support the propeller shaft in a line horizontal with the table of a press.
2. Mark the propeller shaft in order to show which end connects to the transmission and which end connects to the rear axle.



3. Remove the snap rings.

•	Pinch the ends of the snap ring together with a pair of pliers.

•	If a snap 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.




4. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (11/8 in) socket.
5. Press the lower bearing cup out of the yoke ear. Use the J 9522-3 .



6. If the bearing cup is not completely removed, perform the following steps:

6.1.	Lift the cross and insert the J 9522-5 between the seal and the bearing cup.

6.2.	Continue pressing the bearing cup out of the yoke.

7. Rotate the propeller shaft and press the opposite bearing cup out of the yoke.



8. Remove the cross from the yoke.
9. Remove the remaining universal joint parts from the yoke.
10. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner.
11. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring.
12. Inspect the bearing cup bores for burrs or imperfections.

Important: Corrosion or dirt may prevent the bearing cup installation and may prohibit the proper seating of the bearing retainers.

13. Clean the retaining ring grooves.

1. Remove the bearing cups from the new universal joint journals.
2. Coat the needle bearings in the bearing cups with a thin layer of the grease that is present on the journal. Apply the grease with your finger.



3. Install one bearing cup partway 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 seats freely into the bearing cup.



6. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until bearing cup is flush with the yoke ear.
7. Install the opposite bearing cup partway into the yoke ear.
8. Ensure that the trunnions are started straight and true into both bearing cups.
9. Press the opposite bearing cup into the yoke ear.

•	Work the cross all the time.

•	Inspect for free unbinding movement of the trunnions in the bearing cups

Important: If a hang-up or binding is evident, stop pressing. Inspect the needle bearings for misalignment in the bearing cup.

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




10. Install the bearing retainer in the retainer groove.

•	Using the arbor press, continue pressing until you can snap both retainers into place.

•	A small amount of chassis grease may help the snap ring seat in the bearing cup groove.




11. If the retainer does not seat, spring the yoke slightly with a firm blow from a dead blow hammer.