Replacement Service Procedure

Universal Joint Assembly Replacement Service procedure

1. Lift the vehicle up on a hoist.

2. Make a paint line across the companion flange to mark the indexing of the propeller shaft to the differential and transfer case.

3. Remove the propeller shaft assembly from the vehicle following the applicable service manual.





4. Paint straight lines as reference marks on the propeller shaft housing (A1, A2) and the tube & yoke flange (B) as shown in the photo to reference the original location of the components for reassembly.





5. Remove the universal joint snap ring (C) as indicated in the photos.

NOTICE
The preferred method for universal joint removal from the yoke is to use a universal joint press. If a press is not available, please use the procedure outlined in this TSB.





6. Slightly tap the yoke (D) with a hammer to separate the needle bearing cap (E) from the yoke.

CAUTION
Be careful not to damage the yoke due to excessive force.





7. Remove the universal joint needle bearing cap as shown.





8. Repeat steps 6 & 7 for the opposite side to remove the needle bearing caps.

Remove the needle bearing caps from the tube yoke (F).

Remove the universal joint assembly.





9. Fit the new universal joint into the yoke flange (G) and install the needle bearing caps as shown in the photo.

NOTICE
Be careful not to lose any of the needle bearings from bearing caps during the universal joint installation procedure.





10. Install snap rings (H) into grove using a drift punch or equivalent tool.





11. Install the propeller shaft yoke (I) onto the universal joint.





12. Install the needle bearing cap assembly (J) as shown.








13.When installing snap rings (K), use a drift punch or equivalent tool to push them into the grooves as shown in the photos.





14. tap the yoke flange with a hammer to secure and center the newly installed components.

CAUTION
Be careful not to use excessive force when seating the needle bearing caps into the yoke.





15. After reinstalling the universal joint, check that the universal joint operates smoothly on both vertical and horizontal axis.

16. Refer to steps 6-7 in Center Bearing Replacement Procedure in this bulletin.