Replaced U-Joints...can't get the C-clip on one side...
 

The "inboard" (towards the Diff) side...for some reason on both sides of the vehicle......I can only get one of the C-Clips in place. The groove is still hidden by the metal of the driveshaft...and tapping with a socket won't move it in further to access the groove...the C-clip on the opposite side impacts with the wall of the shaft and won't allow anymore motion. So, I was only able to use 3 of the 4 C-Clips on each side.

No problem on the outboard part...both C-Clips went into place fine.

Any suggestions?

Thanks!

AFARR

Take it apart. Good chance one or more of the needle bearings is out of place.

This, or it was a cheaply made joint with too thick of caps or c-clips. My friend had this problem with an autozone axle U-joint.

I'm with the needles being in the way, or get out the micrometer and check it for size... I'm a fan of wire brushing the crap out of stuff before reassembly, maybe try a rat tail file and clean the clip groove? How close is it to setting in place?

The groove is JUST barely hidden (the whole groove) by the 'ears' of the U-joint metal.

I thought it might be due to the 'ears' being slightly bent on one side (since it's the same on both sides of the vehicle and the same part of the U-joint (inboard)).

I'll check it...had to reassemble so I could move the vehicle, but did use anti-seize on all the parts, so should be MUCH easier to take back off.

AFARR

Oh, yeah...before I do the replacement (have the clips sitting in the Jeep for now so I won't forget)...I'm getting a Bearing Press (or a hydraulic press)...make life much easier...!

Sometimes the ears on the shaft get knocked inward when hammering the old ujopint out. Take a drift and place it on the inner part of the ear at the end and give it a good wack, that should move it back into position and allow the grove to be visable. That is also a good way to free up a stiff ujoint that was just replaced.