Mercury 6L2Z-4635-A U-Joint Repair Kit

A press or large vise will be required for this procedure. It may be a good idea to take the driveshaft to a driveline repair shop or machine shop where the universal joints can be replaced for you, normally at a reasonable charge. Remove the driveshaft. Place the driveshaft in a sturdy vise and remove the snap-rings from the spider. Remove the universal joint snap-rings with small pliers. Supporting the driveshaft, place it in position on either an arbor press or 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 cups. Position a socket which is of slightly smaller diameter than the cup on the opposite bearing cup. The universal joint bearing cups can be pressed out with a vise and sockets and use the vise or press to force the cup out, stopping just before it comes completely out of the yoke. Use the vise or large pliers to work the cup the rest of the way out. The bearing cup can be extracted with locking pliers. Transfer the sockets to the other side and press the opposite bearing cup out in the same manner. After the bearings have been removed, lift the spider from the yoke and thoroughly clean all dirt and debris from the yokes on both ends of the driveshaft. Pack the new universal joint bearings with grease. Ordinarily, 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 cup in the yoke. Start the spider into the bearing cup and then partially install the other cup. Align the spider and press the bearing cups 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. This should also be done if the joint feels tight after assembly. Install the driveshaft.

It is advisable to involve a professional in the process of removing and replacing universal joints on a driveshaft. The process involves marking the positions of spiders, the center yoke, and the centering socket. Remove snap-rings and press out bearing cups. Then remove the spider from center yoke. Remove the centering socket yoke, and snap-rings from center yoke, and driveshaft yoke respectively. Press bearing out and separate the spider from the center yoke. Clean all the parts before packing new universal joint bearings with grease. The slip joint must be carefully pulled out of the driveshaft for inspection purposes only. After this, it should be lubricated, reassembled, and secured using a new dust boot seal as well as clamps. Start by placing spider into driveshaft yoke, installing bearing cups, securing them with snap-rings, pack socket relief and ball with grease before pressing center yoke into such position.

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.