Having trouble installing axle shaft u-joint cap into yoke

[nk24]

Working on the front end of a 2005 LJ Rubicon, Dana 44 front axle. Pressed in new ball joints and started working on the axle shaft u-joints. I was able to get one bearing cap in with the snap ring. The other side is 95% of the way in and I can’t seem to get it any farther.

Stubborn cap:

Fully installed cap with snap ring:

I’ve beat on this thing from every angle. The cross is extremely hard to turn at the moment.

Did I bend the ears?

 

[taylormade73]

This is an excellent video tutorial.

 

[mrblaine]

Working on the front end of a 2005 LJ Rubicon, Dana 44 front axle. Pressed in new ball joints and started working on the axle shaft u-joints. I was able to get one bearing cap in with the snap ring. The other side is 95% of the way in and I can’t seem to get it any farther.

View attachment 240435

Stubborn cap:
View attachment 240436

Fully installed cap with snap ring:
View attachment 240437

I’ve beat on this thing from every angle. The cross is extremely hard to turn at the moment.

Did I bend the ears?

You have a needle laying over.

 

[nk24]

You have a needle laying over.

You’re right, as usual. I was able to get the cap off carefully and sure enough a couple of needles were flat on the bottom.

 

[mrblaine]

You’re right, as usual. I was able to get the cap off carefully and sure enough a couple of needles were flat on the bottom.

The best way is to overdrive the first cap through with the u-joint in it holding the needles in place. Then carefully pull the u-joint half way out of that cap so enough of the pin sticks out of the opposite hole that you can slip the cap over them to hold both sets of needle bearings in place.

 

[Cowboy64]

Fwiw..a cheap brake cylinder hone works wonders , cleans the yolk nice an shiny.. tricky to not go to far in or out as the hone is spring loaded.. but sure makes for easier install

 

[mrblaine]

Fwiw..a cheap brake cylinder hone works wonders , cleans the yolk nice an shiny.. tricky to not go to far in or out as the hone is spring loaded.. but sure makes for easier install

For what it is worth, that is a very stupid idea. You need the high interference press fit to keep the caps where they go. You do not want to remove any part of that. What makes the install easier also makes the caps leave easier under load.

 

[Goatman]

Clean up any crap with a wire cleaning brush from your shotgun cleaning kit, but like Blaine said, never remove material where a compression fit it used.