Universal Joint (UJ) Fitting Guide

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How to fit a Universal Joint, the correct procedure.

Place alignment marks on the shaft and flange or yoke. This will make it easier for install later on.

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Remove the internal snap rings by slightly tapping the internal races. Using two screw drivers or a snap ring removal tool, remove the four snap rings from the grooves.
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Remove the universal joints (UJ) bearings by using a universal joint bearing remover and replacer which is available from Toyota at £135.11p!! Sufficiently raise the part indicated by A so that it's does not come into contact with the bearing. Alternatively use a vise and socket combination to push out the UJ caps like RoughTrax used to.
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Clamp the bearing outer race in a vise and tap off the propeller shaft with a hammer. Then remove the bearing on the opposite side in the same procedure as above.
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Install the two removed outer races to the UJ and clamp steady into a vise. Again using the universal joint bearing remover and replacer marked SST or the vise and socket combination to push out the other two bearings from the yoke.
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Clamp the outer bearing race in a vise and tap off the yoke with a hammer. Remove the bearing on the other side in the same procedure.
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Align the marks on the flange or yokes made at the start.
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Fit the new UJ into the yoke using the universal joint bearing remover and replacer or vise and socket combination. Never use excessive force, it should be an interference fit to avoid dropping a needle bearing or damaging the UJ.
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Using the universal joint bearing remover and replacer or the much cheaper vice and socket combo, adjust both bearings so that the snap ring grooves are at the maximum and equal widths.
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Install the two snap rings of equal thickness which will allow 0 - 0.05mm (0-0.0020 inches) axial play. Never re-use the snap rings from an old UJ.
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Using a hammer gently tap the yoke until there is no clearance between the bearing outer race and snap ring. This will also help align the needle bearings after installation.
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Check that the UJ bearings move smoothly and check the bearing axial play which is less than 0 - 0.05mm (0-0.0020 inches). Once the UJ is installed we recommend greasing the UJ. Sometimes it is required to use a Needle Nose Grease Dispenser for manual grease dispensers.
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