REMOVAL & INSTALLATION
See Figures 1 and 2
- Disconnect the negative battery cable. Raise the vehicle and support safely.
- The rear driveshaft is a 3-piece unit, with a front, center and rear propeller shaft. Remove the nuts and insulators from the center support bearing. Work carefully. There will be a number of spacers which will differ from vehicle to vehicle. Check the number of spacers and write down their locations for reference during reassembly.
- Matchmark the rear differential companion flange and the rear driveshaft flange yoke. Remove the companion shaft bolts and remove the driveshaft, keeping it as straight as possible so as to ensure that the boot is not damaged or pinched. Use care to keep from damaging the oil seal in the output housing of the transfer case.
Damage to the boot can be avoided and work will be easier if a piece of cloth or similar material is inserted in the boot.
- Do not lower the rear of the vehicle or oil will flow from the transfer case. Cover the opening to keep dirt out.
- Position the driveshaft in the vehicle, making sure to align the matchmarks at the rear yoke.
- Install the bolts at the rear differential flange and tighten to 22-25 ft. lbs. (30-35 Nm).
- Install the center support bearing with all spacers in place. Tighten the retaining nuts to 22-25 ft. lbs. (30-35 Nm).
- Check the fluid levels in the transfer case and rear differential case.
- Make mating marks on the yoke and the universal joint that is to be disassembled. Remove the snaprings from the yoke with snapring pliers.
- Force out the bearing journals from the yoke using a large C-clamp. Install a collar on the fixed side of the C-clamp. Press the journal bearing into the collar by applying pressure with the C-clamp, on the opposite side.
- Pull the journal bearing from the yoke.
If the journal bearing is hard to remove, strike the yoke with a plastic hammer.
- Press the journal shaft using C-clamp or similar tool, to remove the remaining bearings.
- Once all bearings are removed, remove the journal.
- Apply multi-purpose grease to the shafts, grease sumps, dust seal lips and needle roller bearings of the replacement U-joint. Do not apply excessive grease. Otherwise, faulty fitting of bearing caps and errors in selection of snaprings may result.
Press fit the journal bearings to the yoke using a C-clamp as follows:
- Install a solid base onto the bottom of the C-clamp.
- Insert both bearings into the yoke. Hold and press fit them by tightening the C-clamp.
- Install snaprings of the same thickness onto both sides of each yoke.
- Press the bearing and journal into 1 side by using a brass bar with diameter of 0.59 in. (15mm).
- Measure the clearance between the snapring and the groove wall of the yoke with a feeler gauge. If the clearance exceeds 0.0008-0.0024 in. (0.02-0.06mm), the snap rings should be replaced.