Hi everyone. I failed inspection for a rusty u joint in my front axle. I spent the holiday weekend pulling the whole front end apart as I decided if I have to do some thing I’ll do it the best I can. I have all new tie rods, wheel bearings, ball joints, stabilizer bar links, and u joints.i tried to bang out the joints with a hammer and socket, no go. I ended up getting a ball joint press and pushed out one joint. Ended up bending the end of the shaft so I couldn’t get the new joint to work. Thanks to Amazon I got the new outer end overnight. Now I’m working on the other side and it also won’t push out easily.
yes I removed all four clips from inside the joints.
this side was obviously replaced before. ( different joint). I don’t want to crank down on the ball joint press again and bend this side.
BTW. The original offending joint was perfectly fine. ( damn state inspections).
I’ve watched a bunch of videos and they all show the joint sliding out. Jeep came from WVirginia so not all rusted up.
any ideas are welcome. Thanks in advance.

See the clips in the backround.

 

I have used this method to replace my u-joints on more than one occasion.

 

thanks but didn’t work for me. Either. Would be nice if I had a nice bench mounted vise or even a garage for that matter. lol.
I rent so I’m in the driveway and my landlord is not impressed.

 

Yes I painted it yellow so it can be seen. Right side clip would not lay flat.
I could try to grind that end but I’m worried about imbalance.
same if I could get a torch on it.
I guess I’ll have to find a junkyard shaft and start over. And pray!

 

I have gotten lucky using heat (propane torch) on the yoke part for caps that don't want to move. And then put the ball joint press on, tighten, whck the side of the yoke woth a hammer and repeat until it comes out.

 

I've always done the method in the bleepin video, with or without an actual vise. You could use anything as the prop - x2 2x4 boards, cinderblocks, ive even done this method using a couple 2" drop hitches. I've never been a fan of the presses as I've seen and heard of too many people experiencing exactly what you have - bent ears.

 

I believe the ears are bent in. I use two steel wood wedges, placed in opposition inside the yoke and give a simultaneous tap with two sledge (might be more than a tap) till it's back to normal.

 

Professional machinist here, your ears have bent. Gotta straighten em out a bit. I set the shaft on a flat surface with the bent ear down, bend is facing up. Suitable tool ( round stock, a drift, an extension)and whack the ear end. It will go back, done many this way. Take your time and you will fix it. Ric

 

Stubborn U-joints are a pain! Heat the yoke with a torch and soak it in PB Blaster overnight. If the press isn’t working, grab a big hammer and brass drift smack the yoke ears sideways to break the rust’s grip. If all else fails, grind out the cross to relieve pressure. Sucks bending a good shaft over a dumb inspection fail hang in there, you’ll beat it.

 

I did manage to straighten the bent ear enough that the clip now slid in. The joint seems to move ok. I’m reassembling the front end tonight. I’ll get a sticker on it the. Worry about replacing the shaft if / when I feel any vibrations. Now I have all new brakes( stainless lines, drums, rotors, calipers,…)
a whole new front end,a complete exhaust system( including converter), and rewired dashboard I can’t see any reason it would fail state inspection now.
oh ya my check engine light. Dammit.
thank you all for the suggestions.
If it passes my next step is new bumpers. Ordered a bare steel kit and I’m practicing my welding on those. But that’s for another post.