Driveshaft double cardan joint installation problem

[Rut Row]

I have a 2003 TJ Rubicon. I'm the third owner. To the best of my knowledge, the drivetrain is stock; stock axles, stock driveshafts, stock lockers.

I have an issue and a question.

I had the front driveshaft out to install a Savvy cable shift kit. I decided to replace the u-joints before reinstalling it.

I watched this video multiple times



and everything was going fine until I started installing the new centering yoke.

This is the kit I bought. "CV-996-1 Rebuild Kit for 2003 to 2006 JEEP TJ RUBICON with OEM 1330 series NON GREASEABLE Front CV Driveshaft includes Dana Spicer 211996X NON Greaseable CV Centering Yoke (2) 5-1330X NON greaseable U-Joints (1) 2-86-418 Rubber Boot"

https://www.dennysdriveshaft.com/p2..._for_2003_to_2006_jeep_tj_rubicon_with_o.html

Issue:

The Drive Shaft Dust Seal (p/n 2-86-418) does not fit. The seal is slightly undersized to go over the driveshaft. It fits the centering yoke just fine. I didn't want to press it on as it isn't doesn't appear to be close enough in size. I looked at the original, and there was no dust seal installed. Possibly someone before me had the same issue.

Has anyone encountered this before?

here's the original

Question:

On the axle end of the driveshaft, the ears have a groove in the center with two holes that allow dirt and water in. It does not appear to have broken zirks in the holes. Why did they do this? Should I plug the holes with some RTV? I went ahead and installed the new u-joints.

 

[Blackjack]

A lot of the Rubicon shafts used the old style greaseable centering flange so the parts you purchased will not work. I recommend if the centering flange is needing repaired to replace it with Spicer 211179x.

As for the pinion joint that is a Saginaw style ujoint and caps were originally retained by a resin that was injected into that groove in the yokes. You do not need to worry about it just make sure the retaining rings are seated properly when you install the new ujoint.

 

[Rut Row]

A lot of the Rubicon shafts used the old style greaseable centering flange so the parts you purchased will not work. I recommend if the centering flange is needing repaired to replace it with Spicer 211179x.

As for the pinion joint that is a Saginaw style ujoint and caps were originally retained by a resin that was injected into that groove in the yokes. You do not need to worry about it just make sure the retaining rings are seated properly when you install the new ujoint.

thanks for the response.

since I have nothing to lose, I'll see if I can tap the existing dust seal on. If not, then I'll order a greasable centering flange. I really, really don't want to have to grease that thing. I didn't check if the old one was bad, but it didn't look like it had been greased often. I've only had this TJ a year and my philosophy is change all wearable parts when I work on them for the first time. Now I wish I had ordered a set of Denny's driveshafts.

Update: the shaft is nearly 0.125 larger than the seal. ARGHHH!