U-JOINT REPLACEMENT

1. Place matchmarks on the shaft and yoke.

   Fig. 1: Place matchmarks on the shaft and yoke

2. Using a brass bar and hammer, slightly tap in the bearing and outer race.
   1. Using 2 screwdrivers, carefully remove the 4 snaprings from the grooves as shown.

      Fig. 2: Removing the snaprings from the U-joint grooves

3. Using a puller, push out the bearing from the flange. Sufficiently raise the part indicated as A so that it does not come into contact with the bearing.
   1. Clamp the bearing outer race in a vise, then tap off the flange with a hammer. Remove the bearing on the opposite side in the same procedure.
   2. Install the 2 removed bearing outer races to the spider. With the special tool, push out the bearing from the yoke.
   3. Clamp the outer bearing race in a vise and tap off the yoke with a hammer. remove the bearing on the opposite side in the same procedure.

      Fig. 3: Separating the bearing from the flange using a puller and vise

      Fig. 4: Extract the bearing from the spider

4. Select the bearing according to whether or not there is a drill mark in the yoke selection.
   • Yoke with a drill mark — red color bearing
   • Yoke with no drill mark — no color mark bearing

     Fig. 5: Select the bearing according to the cap color

   To assemble:

5. Apply MP grease to the new bearing and spider. Be careful not to apply too much grease.
   1. Align the matchmarks on the yoke and shaft. fit the spider into the yoke. Using a press, install the new bearing on the spider.
   2. Adjust both bearing so that the snapring grooves are at maximum and equal widths.

      Fig. 6: Always apply MP grease (but not too much) when installing a new bearings to the spider gear

      Fig. 7: Adjust the snaprings so that they are at maximum and equal widths

6. Install the 2 snaprings of equal thickness which will allow 0–0.0020 inch (0–0.05mm) axial play.

   NOTE: Do not reuse the old snaprings. check the charts for sizes.

   1. Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snapring.

      Fig. 8: TMC made snapring chart

      Fig. 9: DANA made snapring chart

7. Make sure the spider bearing moves smoothly. Inspect the spider bearing axial play, 0.0020 inch (0.05mm).

   NOTE: Only install new spider bearings on the flange side in the procedure described.