Dana 44 front u joints !!! help

[cobinder]

Anybody ever have problems installing new u-joints on the axle shafts. I installed them on the inner axles first, no problems. Pressed them (with my harbor freight c-clamp) on the outer axles, when to install the c clip and noticed I had bent the outer axle. I put the u-joint in the freezer the axle was room temp. Where did I go wrong? damn!!!

Anybody have a outer axle they want to sell?

[FormerMember]

The only time I have problems with u-joints is when I get a needle bearing stuck in the cap instead of on the side of the trunnion... I.e. I screwed up the install.

[Batman]

Do you mean you bent the ears that hold the bearing cups? That happens to me everytime I do a u-joint. I just hang the ear on a vice and give it a smack with the hammer, usually gotta do it to both sides. Once the u-joint swivels nice and loose it's good.

[msgross]

I like using a vise on the u-joint install. That and a socket (both larger and smaller) to remove and install. Works great.

PM sent on the axle...

[cobinder]

So batman, I did bend the ears. Are you saying you straightened them after you bent them with a vise? I have to redo the one side and try to install the other u-joint still. I wanna get it figured out before I trash any more parts. Feeling like a hamfist as it is.

FYI. I can see these ears as being the weakest part of a dana 44, there is not much metal compared to the forces that are applied to them.

[Batman]

A vise and a hammer. I'll try to explain since I don't have a picture. If you rest the ear portion on the edge of the vise (or another solid surface, like a metal workbench) so that the u-joint is downward, think opening the ears back up. Then give the solid portion behind the ear a good whack, may have to flip it and repeat on the other ear. Once it's correct the u-joint will swivel nice a free. Hopefully that helps, I doubt you really need to buy a new axle.

[msgross]

Here's the method with the sockets. I like the vise vs. the hammer since it's a squeezing technique rather then the slamming of the hammer. Slips with the hammer end up with bending or breaking the ears...

http://www.dodgeram.org/tech/repair/U_joint/repair.htm

[OLDCHEV4X4]

cobinder, I have run into this same problem. The ears on the axle tend to get tweeked inward during the cap install. I open my big sturdy vice far enough so that the ears are loose in the vice vertically. But the horizontal ears will rest on the jaws. The wife usually comes out and holds the long axle horizontal. Then i take my cold chizel, that has been gound flat, (or a big punch would work), And hit the inside of the lower ear down on both sides. Rotate 180 degres and do it again.
It seems that no matter what method i use to press in the caps, sometimes the ears tweek, and sometimes they dont. Your outer axles are probley ok, Unless you broke a u-joint while you were hard on the gas.
Hope this helps.

[cobinder]

I didn't break one but I gouged the already thin metal with my punch enough that I don't want an even weaker spot (sportin 39" military michilins).

Does make any difference if you install the u=joint in the outer axle first, then the seemingly stronger inner axle?

Roomies, Thanks for all you input.

[john]

It doesn't hurt to sand the bore of the yoke to remove all rust and a little anti sieze will also help to keep the ears from bending.

[CUSTOM/10]

I found after do many of these that you usually bend the ears when removing the old u-joint. There rusted or just really tight and it takes alot of force to get the moving, especially if you trying to get both sides of the joints caps moving at the same time. You can also heat the caps with a torch to get it to expand and break free before you try pressing it out ( Heat just the cap then cool it ) You can straighten them out using a hammer ( I prefer a brass hammer or brass rod ) Meassure the new joint from c clip groove to c clip groove and open up the ears to this meassurement clean the bores, neverseeze and press the new joints in. Good luck !!!

Gary

[cobinder]

I cleaned them with emery cloth, popped the u-joint in the freezer. I did'nt torch them to warm them up I did lay them in the sun (95* day) no lube though.

Just for the record if you do bend them in, it's a bi**h to get the mess apart to get back to square -1

Do you do the inner or outer axle first? or does it matter?

[msgross]

I don't think it matters which one you do first....