Propeller Shaft Universal Joint Replacement (4WD)

Single Use Fasteners and Components Propeller Shaft Universal Joint - [Quantity may vary] Propeller Shaft Universal Joint Spider Bearing Retaining Ring - [Quantity may vary] Special Tools J-9522-3 U-Joint Bearing Separator J-9522-5 U-Joint Bearing Spacer Remover Equivalent regional tools: Special Tools Removal Procedure

1. Place the transmission in neutral service mode. Neutral Service Mode
2. Raise and support the vehicle. Lifting and Jacking the Vehicle
3. Mark the relationship of the propeller shaft to the differential drive pinion gear yoke.

Propeller Shaft Universal Joint Replacement (4WD) — figure 1

4. Rear Propeller Shaft Bolt (1) » Remove [4x]

Propeller Shaft Universal Joint Replacement (4WD) — figure 2

5. Propeller Shaft (1) » Remove Disassembly Procedure

Caution

Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal.

1. Support the propeller shaft in a line horizontal with the table of a press.
2. Mark the propeller shaft component relationship in order to ensure the reassembly is correct.

Propeller Shaft Universal Joint Replacement (4WD) — figure 3

3. Propeller Shaft Universal Joint Spider Bearing Retaining Ring (1) » Remove and DISCARD [4x]
4. If the propeller shaft universal joint spider bearing retaining ring (1) does not readily snap out of the groove in the propeller shaft yoke, tap the end of the propeller shaft bearing lightly in order to relieve the pressure from the propeller shaft universal joint spider bearing retaining ring (1).

Propeller Shaft Universal Joint Replacement (4WD) — figure 4

Note

Some components not shown for graphic clarity.

5. Place the front and rear propeller shaft (3) in the press, so that the lower ear of the front and rear propeller shaft (3) is supported by an appropriate size socket (4). The socket (4) should be deep enough to allow the propeller shaft bearing (2) to completely pass through the bore of the front and rear propeller shaft (3).
6. Place J-9522-3 U-Joint Bearing Separator (1) on the open horizontal front propeller shaft bearings. Press the lower front propeller shaft bearing (2) out of the ear of the front and rear propeller shaft (3) and DISCARD.

Propeller Shaft Universal Joint Replacement (4WD) — figure 5

7. If you do not completely remove the front propeller shaft bearing, lift the propeller shaft universal joint (1) and insert J-9522-5 U-Joint Bearing Spacer Remover (2) between the propeller shaft universal joint and the front propeller shaft bearing you are removing. Continue pressing the front propeller shaft bearing out of the front and rear propeller shaft slip yoke.
8. Rotate the front and rear propeller shaft slip yoke Repeat steps 5 - 7 for the remaining front propeller shaft bearings.
9. Remove the propeller shaft universal joint spider (1) and DISCARD.
10. Inspect and clean the front and rear propeller shaft bearing bores and the propeller shaft retainer grooves from corrosion, dirt or pieces of retaining ring that may prevent proper installation of front propeller shaft bearings.
11. Inspect the front and rear propeller shaft components for wear or damage, replace as necessary. Assembly Procedure

Note

Use all components included with the service kit. Care must be taken when removing the propeller shaft bearings from the propeller shaft universal joint. Make sure the surface that the propeller shaft bearings ride on do not get damaged and remain free of debris. Its best to place the propeller shaft bearings on a clean surface, where they will not be disturbed until installation.

1. Remove the universal joint bearings from the NEW universal joint and inspect inside the propeller shaft bearings to ensure none of the needle bearings become loose or have fallen out.

Propeller Shaft Universal Joint Replacement (4WD) — figure 6

2. Install the NEW propeller shaft universal joint spider (1) into the propeller shaft slip yoke.

Propeller Shaft Universal Joint Replacement (4WD) — figure 7

3. Install the NEW universal joint bearing (2) in either side of the propeller shaft slip yoke (3).
4. Install the propeller shaft universal joint spider until it is seated in the universal bearing.
5. Using an appropriate tool, press in the universal bearing until there is enough space to install the propeller shaft universal joint spider bearing retaining ring.
6. Install the NEW propeller shaft universal joint spider bearing retaining ring (1).
7. Rotate the propeller shaft slip yoke and repeat steps 3-6 for the opposite universal bearing.
8. Rotate the propeller shaft universal joint spider to ensure that the propeller shaft universal joint moves freely. If not, use a hammer and lightly tap the propeller shaft flange to seat the propeller shaft bearing against the universal joint spider bearing retaining ring.

Propeller Shaft Universal Joint Replacement (4WD) — figure 8

9. Position the propeller shaft slip yoke (1) in the propeller shaft (2).

10. Repeat steps 3-8 to install remaining universal bearings. Installation Procedure

11. Install the front and rear propeller shaft (1) and support with an appropriate jack stand.

12. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 2.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 2.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 2.3. Remove loose debris from internal and external threads using compressed air. 2.4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers

13. Align the reference marks made between the differential drive pinion gear yoke and the propeller shaft (2).

Caution

Refer to Fastener Caution.

4. Install the 4 rear propeller shaft bolts (1) and tighten in a crisscross pattern. Fastener Specifications.
5. Remove the support and partially lower the vehicle, open the door and place the vehicle in park.
6. Fully lower the vehicle.