Replacing U-joints on front drive shaft - problem

[brianmc]

So I've removed the front drive shaft and am replacing the U-joints. I removed the U-joint connecting to the pumpkin without issue, however the one at the other end that bolts into the T-case is giving me a hard time.

I removed the clips and did everything the same way as the other, except I get about 85% of the way through and the darn thing just wont budge anymore. It appears that the, I'm sure how to describe it so I'll call it a revolving joint, that separates the joints at that end creating that large knuckle is preventing it from coming out. Is there secret to changing that one in particular, and also, is it possible to change the U-joint that connects that knuckle looking thing to the drive shaft?
The joint to the left in this picture

Thanks, Brian

 

[4x4junkie]

As I remember, you have to let the inner part (socket yoke) go along with the joint as you press it out (kindof have no choice really). Right at the point where the body of the joint and yoke are fully bound against the side of the H-yoke, you should then be able to grab the protruding u-joint cap with a pair of channellocks or similar and twist & pull it out (that's how it worked on mine anyway). Then press it the other way and repeat for the other side cap. Once the 1st joint is completely out, the socket yoke will also come right out, and then you can press the 2nd joint out.

Be sure to pack the ball & socket assembly full of grease too when you put it all back together (turning the ball sideways in the socket should open a gap where you can then pack the grease down into)


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[brianmc]

I am unable to get the last U-joint out. The one that connects the yoke to the shaft in the middle there. I've had it nearly half way out but then it just wont budge. Is a press absolutely necessary? Also, I took it to a shop today to ask them to look at it to see if they could just press it out for me for a certain fee and what I was told was that that U-joint is not changeable and you have to replace that whole yoke and the only way to do that is to take it somewhere to have it chopped off and a new one welded on. I didn't want to say he was full of crap but I thought for sure you could change it because it's just another U-joint and I know the first gens don't have any cv joints. Any recommendations as to how I should go about getting it out? I have a torch, been hammering, don't own a press and don't really want to spend 30 bucks on one if I dont have too.
Thanks,
Brian

 

[Willard]

It can be done, I did it, but it took a lot of prying and hammering and such to get it out. There really isn't enough room in there to get it out, but somehow I got it done. I wish I could tell you how, but I don't remember.

Just don't give up, that's all I can tell you. It can be done.

 

[4x4junkie]

The 2nd joint I recall being the easier of the two.

Which way are you trying to take it out from? Maybe try it from the other way (in other words, if you're trying to take it out from the H-yoke side first, maybe try it from the shaft side instead or vice-versa. I do seem to recall it did have to come apart a certain way).

And yes, that guy you spoke to was an idiot. A good driveline shop could rebuild the whole thing for you as long as the socket yoke pin on the end of the shaft isn't damaged (all new joints and seals).

 

[brianmc]

Don't have much time to fix this, and each time I work on it I guess I try to hurry and end up messing something up. Now the problem is in the last U-joint. I got the yoke back together with all 4 caps in, and now the one that goes to the T-case is giving me a hard time. I can't get the two ends to line up straight. I guess I can't get the spring part to line up correctly... Any tips here?