Ford F2AZ-4635-C U-Joint Repair Kit

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A local dealer service department, service station, or machine shop.

Pack the new universal joint bearings with grease.

Driveshafts have a "slip yoke" at the front end that inserts into the extension housing of the transmission or transfer case. On two-piece rear driveshafts, a center bearing supports the driveline. The rear end of all rear driveshafts connects to the rear axle's differential pinion flange using a flange yoke with four bolts. Front driveshafts on 4WD models may have a slip yoke at either the front or rear end, depending on the vehicle type.

Remove the snap-rings retaining the bearing caps, marking their positions beforehand. Start by removing the bearing caps in the center yoke and then the driveshaft yoke, ensuring proper alignment. Replace the centering ball and dust cover on the companion flange. Disassemble the center yoke and driveshaft yoke, installing a new spider bearing in the driveshaft yoke. Insert new caps and seals, ensuring the grease fitting faces away from the center yoke. Press the caps into place, align the marks, and secure with sockets. Assemble the centering stud, center seal, and centering spring, connecting the companion flange to the center yoke with a new spider. Press in the caps and install new snap-rings as needed.

The driveshaft is a tube that runs between the transfer case or transmission and the rear axle or front axle, with universal joints at either end that allow power to be transmitted to the wheels at varying angles. Some driveshafts have a splined lip yoke at one end that fits into the transmission extension housing, while others have a slip yoke as part of the driveshaft, allowing the length of the driveshaft to change to compensate for suspension movement. Models with a slip yoke at the front of the driveshaft use an oil seal to prevent fluid leakage and keep contaminants out of the transmission. The driveshaft assembly requires minimal service, with universal joints on models without grease fittings being lubricated for life and needing replacement if problems arise. The driveshaft is a balanced unit, so it's important to keep it clean and check for damage and securely attached balancing weights. Problems with the driveshaft are usually indicated by noise or vibration while driving, and a road test can help determine if the driveshaft is the issue. Worn universal joints can be checked by driving the vehicle slowly in high gear, then accelerating and listening for a clunking or knocking noise, or by driving at a speed of about 10 to 15 mph, placing the transmission in neutral, and listening for abnormal driveline noises. The vehicle can also be raised and supported on jackstands, with the transmission in neutral, to manually turn the driveshaft and watch the universal joints for excessive play.

Single-cardan U-joints on some 1970 through 1988 models and all 1989 and later models can be replaced by following these steps. First, remove the driveshaft and snap-rings from the spider. Place the driveshaft on a workbench equipped with a vise and use a pipe or large socket to press out the bearing caps. Transfer the sockets to the other side and press out the opposite bearing cap. Pack the new universal joint bearings with grease and position the spider in the yoke. Install the bearing caps and snap-rings, then fill the joint with grease. Finally, reinstall the driveshaft. For double-cardan U-joints, remove the snap-rings and mark the relationship of the components. Press out the bearing caps and remove the centering ball and dust cover. Install new components and press in the bearing caps. Install new snap-rings and reassemble the front U-joint by removing the centering socket.

A press or large vise will be required for this procedure. It may be advisable to take the driveshaft to a local dealer service department, service station or machine shop where the universal joints can be replaced for you, normally at a reasonable charge. Remove the driveshaft as outlined previously. Using a small pair of pliers, remove the snap-rings from the spider. A pair of needle-nose pliers can be used to remove the universal joint snap-rings. Supporting the driveshaft, place it in position on a workbench equipped with a vise. Place a piece of pipe or a large socket with the same inside diameter over one of the bearing caps. Position a socket which is of slightly smaller diameter than the cap on the opposite bearing cap. To press the universal joint out of the driveshaft yoke, set it up in a vise with the small socket pushing the joint and bearing cap into the large socket. Use the vise or press to force the cap out, stopping just before it comes completely out of the yoke. Use the vise or large pliers to work the cap the rest of the way out. Transfer the sockets to the other side and press the opposite bearing cap out in the same manner. Pack the new universal joint bearings with grease. Specific instructions for lubrication will be included with the universal joint servicing kit and should be followed carefully. Position the spider in the yoke and partially install one bearing cap in the yoke. Start the spider into the bearing cap and then partially install the other cap. Align the spider and press the bearing caps into position, being careful not to damage the dust seals. Install the snap-rings. If difficulty is encountered in seating the snap-rings, strike the driveshaft yoke sharply with a hammer. This will spring the yoke ears slightly and allow the snap-rings to seat in the groove. If the snap-ring will not seat in the groove, strike the yoke with a brass hammer - this will relieve the tension that has set up in the yoke, and slightly spring the yoke ears. This should also be done if the joint feels tight when assembled. Install the grease fitting and fill the joint with grease. Be careful not to overfill the joint, as this could blow out the grease seals. Install the driveshaft, tightening the companion flange bolts to the torque.

Remove the snap-rings retaining the bearing caps, marking their positions beforehand. Start by removing the bearing caps in the center yoke and then the driveshaft yoke, ensuring proper alignment. Replace the centering ball and dust cover on the companion flange. Disassemble the center yoke and driveshaft yoke, installing a new spider bearing in the driveshaft yoke. Insert new caps and seals, ensuring the grease fitting faces away from the center yoke. Press the caps into place, align the marks, and secure with sockets. Assemble the centering stud, center seal, and centering spring, connecting the companion flange to the center yoke with a new spider. Press in the caps and install new snap-rings as needed.

It is recommended to consider professional assistance from a driveline repair or machine shop.

A driveshaft is a tube, or a pair of tubes, that transmits power between the transmission and the differential in the rear axle. Universal joints are used at both ends of all driveshafts, and right behind the center bearing on two-piece rear driveshafts. A universal joint, or U-joint, is a double-pivoted connection for transmitting power from a driving to a driven shaft through an angle. Most U-joints are the single-cardan type. A double-cardan U-joint is used on 4WD sport utility models without air suspension. All rear driveshafts employ a "slip yoke" at the front, which slips into the extension housing of the transmission or transfer case. A center bearing supports the driveline on vehicles with a two-piece rear driveshaft. The rear end of all rear driveshafts is connected to the rear axle differential pinion flange by a flange yoke with four bolts. Front driveshafts on 4WD models employ a slip yoke at the front end of the driveshaft on trucks, but at the rear end on sport utility vehicles. The driveshaft assembly requires very little service. The universal joints are lubricated for life and must be replaced if problems develop. The driveshaft must be removed from the vehicle for this procedure. Since the driveshaft is a balanced unit, it's important that no undercoating, mud, etc. be allowed to stay on it. When the vehicle is raised for service it's a good idea to clean the driveshaft and inspect it for any obvious damage. Also, make sure the small weights used to originally balance the driveshaft are in place and securely attached. Whenever the driveshaft is removed it must be reinstalled in the same relative position to preserve the balance. Problems with the driveshaft are usually indicated by a noise or vibration while driving the vehicle. A road test should verify if the problem is the driveshaft or another vehicle component. If you suspect trouble, inspect the driveline.

Partially install one bearing cap, start the spider into the bearing cap, partially install the other cap, and then press the bearing caps into position.

A press or large vise will be required for this procedure. It may be advisable to take the driveshaft to a local dealer service department, service station or machine shop where the universal joints can be replaced for you, normally at a reasonable charge. Remove the driveshaft as outlined previously. Using a small pair of pliers, remove the snap-rings from the spider. A pair of needle-nose pliers can be used to remove the universal joint snap-rings. Supporting the driveshaft, place it in position on a workbench equipped with a vise. Place a piece of pipe or a large socket with the same inside diameter over one of the bearing caps. Position a socket which is of slightly smaller diameter than the cap on the opposite bearing cap. To press the universal joint out of the driveshaft yoke, set it up in a vise with the small socket pushing the joint and bearing cap into the large socket. Use the vise or press to force the cap out, stopping just before it comes completely out of the yoke. Use the vise or large pliers to work the cap the rest of the way out. Transfer the sockets to the other side and press the opposite bearing cap out in the same manner. Pack the new universal joint bearings with grease. Specific instructions for lubrication will be included with the universal joint servicing kit and should be followed carefully. Position the spider in the yoke and partially install one bearing cap in the yoke. Start the spider into the bearing cap and then partially install the other cap. Align the spider and press the bearing caps into position, being careful not to damage the dust seals. Install the snap-rings. If difficulty is encountered in seating the snap-rings, strike the driveshaft yoke sharply with a hammer. This will spring the yoke ears slightly and allow the snap-rings to seat in the groove. If the snap-ring will not seat in the groove, strike the yoke with a brass hammer - this will relieve the tension that has set up in the yoke, and slightly spring the yoke ears. This should also be done if the joint feels tight when assembled. Install the grease fitting and fill the joint with grease. Be careful not to overfill the joint, as this could blow out the grease seals. Install the driveshaft, tightening the companion flange bolts to the torque.