Ford F2TZ-4635-B U-Joint Repair Kit

To service the outer snap-ring type universal joint, first, remove the driveshaft and mark the joint yokes' positions. Extract the snap-rings from the bearing cups, then use sockets or pipe pieces in a vise to press one cup while displacing the opposite one into a larger socket, gripping and twisting the bearing cup out with pliers. Clean the yoke and inspect for damage, then obtain a repair kit that includes trunnion, cups, needle rollers, seals, washers, and snap-rings. Before reassembly, pack grease into the trunnion reservoirs and needle bearings without displacing them. Position the trunnion in the yoke, partially install one cup, insert the trunnion, partially install the opposite cup, center the trunnion, and press both cups into place using sockets slightly smaller than the bearing cups, ensuring needle bearings remain in place. Install the snap-rings and align the shaft yokes to install the other bearing cups similarly. For the injected plastic type, destroy the production line plastic retainers and fit conventional snap-ring repair kits. Support the joint yoke in a press and use a forked tool to apply pressure to eject the bearing cups, then twist them out with a vise. Clean any plastic remnants and obtain a repair kit with a prelubricated trunnion assembly and other components. Assemble the joint, noting that snap-rings are installed inside the yokes, and if the joint is stiff after reassembly, apply hammer blows to free the bearing cups. For the double cardan type constant velocity joint, use an inspection kit to dismantle the joint for inspection, marking the flange and coupling yokes for reassembly. Disengage the flange yoke and trunnion from the centering ball, remove the seal, washers, spring, and ball seats, then clean and inspect all components for wear, replacing any damaged parts. Remove plastic from the coupling yoke groove if necessary, inspect and replace the centering ball if damaged, and press a new ball onto the stud. Lubricate all parts with grease from the repair kit and insert them into the ball seat cavity in the correct order, lubricate the seal lips, and press it into the cavity, filling it with grease. Finally, install the flange yoke to the centering ball, ensuring alignment marks are correct, and install the trunnion caps as previously described.

Universal joints are Power transmission components that couple two shafts that are in turn rotating at different angles. It has two sleeves on each side connected by a bar called the trunnion and are cup-ended with needle bearing. Snap-rings, installed either inside or outside the bearing cups, fix the assembly. Universal joints are of two broad categories somewhat different in terms of retention. The first kind has one joint which is retained to its yoke with internal or external snap rings. The second kind is referred to as a 'double cardan' and comes equipped with two universal joints, a centering socket yoke, as well as a center yoke, for 4WD models which deals with high torque loads and steep drive-line angles as found in Broncos and certain pickups.

Greasing of the universal joint is vital to driveline efficiency; there should be a recommended schedule of lubrication. The signs of wear in needle roller bearings can be detected by vibration, noise especially during acceleration, and in the extreme cases there may be metallic squeaking, then grating and shrieking as the bearings wear out. In checking for wear of needle bearings when the driveshaft is in place, on attempt to rotate the shaft with one hand while holding the rear axle flange with the other around the front and rear half couplings should be made. Also, in the space between the universal joint and the driveshaft or flange, a loose pry bar may be observed when pried in radial and axial directions, particularly if the car is left in gear. Another test for wear is raising the shaft by having a look at whether or not the yokes of the joints have shifted. In case the checker plate appear to be worn in any way it is recommended that the universal joints should be replaced with new ones.

Place the driveshaft in a vise with a small socket pushing the joint and bearing cap into a larger socket.