Axle U-Joints Breaking During Install

[howeitsdone]

So I've completely broken both of my new axle u-joints during the install and wondering what I'm doing wrong.

 

I take all the caps off, insert into the holes, put a cap over one of the fittings and begin to press in with my ball joint press. That went fine on both. The problem is when installing the opposite side. When I'm pressing in the other side it 'pops' and then I'm left with what you see in the photo. Anybody know what I'm doing wrong?

 

[jdog]

What are you using as a back stop? Left side looks like it's a socket

[howeitsdone]

So the right one I did without anything; just left it open to allow movement. The left one I basically used a socket. It's an adapter for my press.

[Jeep Driver]

I'm wondering if the ears of you stub shaft are bent now?

 

U joints don't take a lot of pressure to press in. A lot of guys use a vice or a hammer. 

[silvertwinkiehobo]

It's why I don't use a press that develops a metric f-ton of force...you have to be careful you do not get one of the needle bearings caught under the end of the spider. It may deform, but it will not flatten out, so having that much force on the inside of the cap with no center support could do that. And, if you do use a socket, use the back end of it, which will give a bit more support to the cap.

[jeepmjga]

Maybe try just using a 4 lb instead of ball joint press. They should slide right in. Whats your process?  This guy has a good vid if have a bench vise.  A little messy as far as needle bearings go. 

 

 

[howeitsdone]

36 minutes ago, Jeep Driver said:

I'm wondering if the ears of you stub shaft are bent now?

 

I'm thinking so too. One was really difficult to get out once the caps were removed

 

5 minutes ago, jeepmjga said:

Maybe try just using a 4 lb instead of ball joint press. They should slide right in. Whats your process?

 

I used the press for the driveshaft with no issues. Figured this would be the same process.

1. Press one side in a bit past flush
2. Press in the other side until almost in completely
3. Insert clip into the first cap
4. Press a bit more until able to install the 2nd clip

I had another set that I had just bought that I thought were wrong but turned out correct. So I tried using the hammer instead, but the pins shot out of one of the caps during the process. So after looking at the good Spicer caps I decided to use one as a replacement. It's a tight fit, but managed to get it together. Not permanent, but should work for the next week or so.

 

Just not sure what I'm doing wrong. Seems like everyone gets these installed pretty easily.

[JustEmptyEveryPocket]

Did you shine where the caps go with emery cloth? Also, did you run a file around the rims to make sure there were no burrs to get caught on? On reassembly did you use some type of lube? Otherwise, I would bet on issues with your shafts themselves. 

[jdog]

I put them in the freezer a day or so before

[Jesse J]

7 hours ago, jdog said:

I put them in the freezer a day or so before

This was actually the last thing I though about last night. I also though about leaving the shafts in the sun

[howeitsdone]

Install on the 2nd shaft went much better. I greased up the outside of the caps to help. Thank for the help!

 

Now I'm thinking I will need a new stub. It turns out it's bent just enough so that the clip can't fit. So I'll look to source one today rather than just grind it down.

 

 

So what did I learn? If there is too much pressure from the press on the u-joint, they won't survive. Back out the press and figure out why the cap isn't seating. I'm sure I needed to take a wire brush to the holes prior to installation and then grease them up. I also had much better luck this time with the hammer method to get them seated properly. I think the grease really helped. I just used the press to finish them off.

[JustEmptyEveryPocket]

Its a great life lesson: Use lube. Applies to so many things . . .

[Jeep Driver]

22 minutes ago, PocketsEmptied said:

Back out the press and figure out why the cap isn't seating.

OP, 

 

I learned to do Ujoints using a simple C-clamp. You will not destroy anything with the limited strength of your wrist. 

 

Vid provided here, I cringe when I see people beating $#!& to death with a hammer........do not beat anything to death. 

 

You are correct, this is a most important lesson, be gentle, force nothing. 

 

You need a die grinder and flap wheel.......if you don't have one, use a Dremel, if you don't have one of those, buy one. 

And you don't' want to remove material, just clean and polish. 

 

I have a 20T press, I use it but I also know when to back off, take a look, if something isn't right, I stop and make it right.