Ford C3AZ-4635-J U-Joint

Remove the driveshaft and clean away any dirt and foreign matter from the universal joint area. Remove the snap-rings from the U-joint end caps. Use Ford tool T74P-4635 to remove the bearing caps from the U-joint yoke; if this tool or an equivalent is not available, a vise, a selection of sockets, and a quantity of bearing grease are required. Open the vise wide enough to accommodate the U-joint and two sockets, selecting a socket larger than the bearing cup to allow space for the cup to be pushed into it, and a second socket as close as possible in size to the cup's outer diameter. Apply pressure to the vise, forcing the bearing cup from the yoke into the larger socket, then remove the bearing cup from the yoke. Clean the yokes with a suitable solvent, and if the bearings are to be reinstalled, clean and re-grease them, filling the cups one-third full with grease. Using new seals, start the bearing cup into the yoke and press it into position so that the cup is ¾ inch below the yoke surface, then install the bearing snap-rings. Check the U-joint for free movement in all directions and replace the driveshaft to the vehicle.

This is easier than for the front universal joint as only two spider cups have to be removed. The Remaining cups simply slide off the spider journals, these being held in position by the two U-bolts and small lips on the pinion flange cup locations. Overhaul is otherwise.

Wear in the needle roller bearings is characterised by vibration in drive-line, clunks' on taking up the drive, and in extreme cases of lack of lubrication, metallic squeaking, and ultimately grating and shrieking. It is easy to check if the needle roller bearings are worn with the driveshaft in position, by trying to turn the shaft with one hand, the other hand holding the rear axle pinion flange when the rear universal joint is being checked, and the front half coupling when the front universal is being checked, Any movement between the driveshaft and the front and rear half couplings is indicative of considerable wear. If worn, the old bearings and spiders will have to be discarded and repair kit, comprising new universal joint spiders, bearings, oil seals,and retainers purchased. Check also by trying to lift the shaft and noticing any movement in the joints. Examine the driveshaft splines for wear. If worn it will be necessary to purchase a new front half coupling, or if the yokes are badly worn, an exchange driveshaft. It is not possible to fit oversized bearings and journals to the trunnion bearing holes.

For this procedure, a press or a large vise will be necessary and it may be simpler to take the driveshaft to a local dealer or a machine shop for replacement of the universal joint at a reasonable cost. First disassemble by taking out the driveshaft. By now you would have realized that some disassembling of the spider may be necessary; using a small pair of pliers remove the snap-rings from the spider, you might need to use needle-nose pliers here. Secure the driveshaft and align it in such a manner that can be placed on an arbor press or placed on the workbench with vise. Put one bearing cap with a piece of pipe or with another large socket where the inside diameter is the same at one side of the crank and fit another socket slightly smaller over the cap on the other side of the crank. With the vise or press, apply pressure until the cap partially comes out of the yoke but do not fully remove it out; the fully removal has to be done with the vise or large pliers. Remove the bearing caps on the other side and place the sockets on the opposite side again pushing out the other bearing cap in the same way. After that, lubricate the new universal joint bearings with the help of grease that has to be packed with the servicing kit, if there are special instructions where to grease the bearings. Fit one of the bearing caps partly into the yoke and set the spider into the cap, then start the spider into the other cap and fit it part way. Position the spider and engage the bearing caps and bear in mind that the dust seals should not be marred. Place the snap-rings and in case of a hard time getting them to seat back into the groove, slight tapping of the driveshaft yoke will do the trick. If the snap-ring still does not seat it is advisable to use brass hammer to spring the yoke ears slightly. Fit in a grease fitting and then pump the joint with grease but don't overfill so you don't end blowing out the grease seals. Last, but not the least is the installation of the drive shaft followed by the tightening of the flange bolts to a recommended torque value.

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.

Clean away all traces of dirt and grease from the snap-rings located on the ends of the bearing cups. Remove the snap-rings by pressing their open ends together with a pair of pliers, and lever them out with a screwdriver, If they are difficult to remove, tap the bearing cup face resting on the top of the spider with a soft-faced hammer which will ease the pressure on the snap-ring. Take off the bearing cups on the driveshaft yoke. To do this select two sockets from a socket spanner set, one large enough to fit completely over the bearing cup and the other smaller than the bearing cup. Open the jaws of the vise and with the sockets opposite each other and the universal joint in between, tighten the vise and so force the narrower socket to move the opposite cup partially out of the yoke into the larger socket. Remove the cup with a pair of pliers. Remove the opposite cup.and then free the yoke from the driveshaft. To remove the remaining two cups now repeat the instructions, or use a socket and hammer. Recover the thrust bearing from inside each cup and remove the seal from the base of each spider journal. Before reassembling, using new parts as necessary, thoroughly clean out the yokes and journals. Fit new oil seals to the spider journals and then assemble the needle rollers in the bearing cups with the assistance of some thin grease. Fill each bearing cup about one third full with a universal grease.not forgetting to refit the thrust bearings first. Refit the bearing cups on the spider and tap the bearings home so that they lie squarely in position. Replace the snap-rings and settle the cups by tapping the whole assembly with a soft faced hammer. Check that angular movement of the universal joint is free throughout its full range without signs of stiffness.

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.

Wear in the universal joints is indicated by driveline vibration, "clunking" noises during initial movement, and metallic squeaking or grating sounds. A harmonic rumbling at highway speeds may also signal issues with the universal joint or driveline bearings. To check the condition of the universal joint, park the vehicle on a level surface with the transmission in gear or 'Park', block the wheels, and engage the parking brake. From underneath the car, hold the axle pinion flange with one hand while moving the driveshaft with the other; noticeable looseness in the universal joint area suggests that the joint is worn and needs replacement. This check should also be repeated at the front of the driveshaft, focusing on the universal joint condition and any wear or looseness in the sliding spline section of the yoke.

Press a new ball onto the stud until it seats firmly on the stud shoulder, ensuring no damage occurs to the ball.

Universal joints are mechanical couplings that connect two rotating components that meet each other at different angles.

Another method to check for universal joint wear is to. Use a pry bar inserted into the gap between the universal joint and the driveshaft or flange. Leave the vehicle in gear and try to pry the joint both radially and axially. Any looseness should be apparent with this method.

The steps to replace double-cardan U-joints are as follows. Remove the snap-rings and mark the relationship of the components. Press out the bearing caps. Remove the centering ball and dust cover. Install new components. Press in the bearing caps. Install new snap-rings. Reassemble the front U-joint by removing the centering socket.

With grease.