Rover
08-22-2008, 12:11 AM
Start out by properly chaking the tires and placeing the trans/tcase in neutral
The need to raise the vehicles wheels off the ground depends on the vehicle
Place a pry bar in the joint and loosen the nuts on the u joint straps
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0078.jpg
After both straps are removed use a pry bar to remove the drive shaft from the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0079.jpg
*Tip* If you are removing a d shaft and not replacing one of the joints, wrap tape around it like shown so that you do not loose any of the caps or needle bearings
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0080.jpg
Red dust like this is common when the joint runs out of greese and the needle bearings turn to dust. This joint became very stiff and squeeked when the vehicle drove down the road
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0081.jpg
here is the u joint with the cap removed
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0082.jpg
Next step is to remove the hotchkis clips that retain the u joint in the driveshaft yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0083.jpg
I use a pair of plyers or side cutters and a small screwdriver to remove the clips. Use saftey glasses when removing these clips, the usually come out at high speed and can hit you in the eyes, no good
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0084.jpg
Repeat this for all the clips on the drive shaft
here you can go acople different ways with removing the joint from the dshaft, i will show you how to do it with a vice and then a press
Vice method
I dont have a vice in this garage so I used to plates to mimick vice jaws
Place the joint and shaft into the jaws as shown
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0085.jpg
Hit the yoke as shown, DO NOT HIT THE SHAFTS TUBE
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0086.jpg
Hit the yoke untill the joint bottoms out and the cap becomes loose
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0087.jpg
You may need to use some plyers to remove the cap from the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0088.jpg
what the joint should look like now
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0089.jpg
Rotate the d shaft 180 and repeat
Now its time to remove the joint from the shaft
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0090.jpg
Very lightly use a file to remove any rust/corrosion from the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0091.jpg
Take the new u joint and make sure it matches the old joint
Then take the new joint apart and lay out the pieces
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0092.jpg
take one of the caps and carefully tap it into the yoke. check to make sure you have not lost/moved any of the needle bearings
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0093.jpg
Install the joint and place it in the new cap
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0094.jpg
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0095.jpg
Carefully tap the oppostie cap into the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0096.jpg
Lay one end of the shaft onto a flat surface and take a old socket alittle smaller than the face of the cap and hit the cap untill the hotchkis clip can be installed.
if the cap becomes had to hit stop immediatly, one or more needle bearings may have fallen out of the pack and are stopping the cap from seating fully. remove the cap and inspect for missing needle bearings
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0097.jpg
install the clip into the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0098.jpg
Flip the shaft 180 and repeat
place the joint back into the vice jaws and lightly tap on the yoke to seat the needle bearings
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0099.jpg
rotate the shaft 180 and repeat, the joint should rotate freely with some resistance
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0100.jpg
install the greese fitting and greese the joint
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0115.jpg
Press method
Im going to start this one with the hotchkis clips already removed
Find a large socket or orther item big enough so that the u joint cap can fit through it but still contacts the yoke. I use a toyota solid pinion spacer from a toy 8" differential for most joints
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0101.jpg
Find a socket alittle smaller than the face of the u joint cap
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0102.jpg
place you big socket/space on the press plates
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0103.jpg
place the d shaft joint and small socket onto the press
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0104.jpg
press the cap untill the joint bottoms out in the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0105.jpg
you may need to use some plyers to remove the cap
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0106.jpg
Flip the d shaft 180 and repeat
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0107.jpg
Remove the joint from the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0108.jpg
Lightly file any rust/corrosion from the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0109.jpg
carefully tap one of the new caps into the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0110.jpg
make sure the needle bearings are good
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0111.jpg
place the joint into the yoke and sit the installed cap on a flat surface
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0112.jpg
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0113.jpg
Carefully tap the oppostie cap onto the joint and then hit it on enough to install the clip
if it gets tough stop and remove the cap, a needle bearing might have fallin into the joint
see it happins to the best of us
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0114.jpg
When finished install the greese fittings and greese the joint
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0115.jpg
Reinstall the driveshaft and make sure to tighten all the u joint straps
your ready to go
any qestions or comments dont hesitate to send me a pm. Want to see a write up on something that hasent been covered let me know, i can try to do one for ya
Nick-Double Doppleganger Fab and Repair
The need to raise the vehicles wheels off the ground depends on the vehicle
Place a pry bar in the joint and loosen the nuts on the u joint straps
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0078.jpg
After both straps are removed use a pry bar to remove the drive shaft from the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0079.jpg
*Tip* If you are removing a d shaft and not replacing one of the joints, wrap tape around it like shown so that you do not loose any of the caps or needle bearings
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0080.jpg
Red dust like this is common when the joint runs out of greese and the needle bearings turn to dust. This joint became very stiff and squeeked when the vehicle drove down the road
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0081.jpg
here is the u joint with the cap removed
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0082.jpg
Next step is to remove the hotchkis clips that retain the u joint in the driveshaft yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0083.jpg
I use a pair of plyers or side cutters and a small screwdriver to remove the clips. Use saftey glasses when removing these clips, the usually come out at high speed and can hit you in the eyes, no good
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0084.jpg
Repeat this for all the clips on the drive shaft
here you can go acople different ways with removing the joint from the dshaft, i will show you how to do it with a vice and then a press
Vice method
I dont have a vice in this garage so I used to plates to mimick vice jaws
Place the joint and shaft into the jaws as shown
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0085.jpg
Hit the yoke as shown, DO NOT HIT THE SHAFTS TUBE
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0086.jpg
Hit the yoke untill the joint bottoms out and the cap becomes loose
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0087.jpg
You may need to use some plyers to remove the cap from the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0088.jpg
what the joint should look like now
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0089.jpg
Rotate the d shaft 180 and repeat
Now its time to remove the joint from the shaft
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0090.jpg
Very lightly use a file to remove any rust/corrosion from the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0091.jpg
Take the new u joint and make sure it matches the old joint
Then take the new joint apart and lay out the pieces
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0092.jpg
take one of the caps and carefully tap it into the yoke. check to make sure you have not lost/moved any of the needle bearings
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0093.jpg
Install the joint and place it in the new cap
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0094.jpg
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0095.jpg
Carefully tap the oppostie cap into the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0096.jpg
Lay one end of the shaft onto a flat surface and take a old socket alittle smaller than the face of the cap and hit the cap untill the hotchkis clip can be installed.
if the cap becomes had to hit stop immediatly, one or more needle bearings may have fallen out of the pack and are stopping the cap from seating fully. remove the cap and inspect for missing needle bearings
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0097.jpg
install the clip into the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0098.jpg
Flip the shaft 180 and repeat
place the joint back into the vice jaws and lightly tap on the yoke to seat the needle bearings
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0099.jpg
rotate the shaft 180 and repeat, the joint should rotate freely with some resistance
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0100.jpg
install the greese fitting and greese the joint
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0115.jpg
Press method
Im going to start this one with the hotchkis clips already removed
Find a large socket or orther item big enough so that the u joint cap can fit through it but still contacts the yoke. I use a toyota solid pinion spacer from a toy 8" differential for most joints
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0101.jpg
Find a socket alittle smaller than the face of the u joint cap
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0102.jpg
place you big socket/space on the press plates
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0103.jpg
place the d shaft joint and small socket onto the press
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0104.jpg
press the cap untill the joint bottoms out in the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0105.jpg
you may need to use some plyers to remove the cap
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0106.jpg
Flip the d shaft 180 and repeat
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0107.jpg
Remove the joint from the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0108.jpg
Lightly file any rust/corrosion from the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0109.jpg
carefully tap one of the new caps into the yoke
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0110.jpg
make sure the needle bearings are good
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0111.jpg
place the joint into the yoke and sit the installed cap on a flat surface
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0112.jpg
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0113.jpg
Carefully tap the oppostie cap onto the joint and then hit it on enough to install the clip
if it gets tough stop and remove the cap, a needle bearing might have fallin into the joint
see it happins to the best of us
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0114.jpg
When finished install the greese fittings and greese the joint
http://i117.photobucket.com/albums/o74/landrollover/tech/drive%20shaft%20u%20joint%20swap/IMGA0115.jpg
Reinstall the driveshaft and make sure to tighten all the u joint straps
your ready to go
any qestions or comments dont hesitate to send me a pm. Want to see a write up on something that hasent been covered let me know, i can try to do one for ya
Nick-Double Doppleganger Fab and Repair