The Clips wont fit in one side of the new U-Joints I installed on my front Axles . Can I Spot weld the end that I cant get the Clip in? These are Greasable U-Joints .

 

Yes just do it quick and cool it down afterwards.

 

The ear is bent slightly, or a needle bearing fell out and got crushed. Doublecheck if you havent already because you dont want bits and pieces grinding away in there. I ran into both issues atleast once. A needle fell out and the clip wouldnt fit one. And the ear was bent on another.

 

The Ear got bent when I removed the old U-Joint

 

weld away - this is more common than you might think. Especially with some D60 guys out there. Typically ditch the factory style C-clips in favor of full circle clips. When the caps start spinning in the ears you throw a little weld on them - helps keeps them in place

 

You need to learn a better method of removing the u-joints.

My method is to support the sides of the cross on either blocks or a piece of u-channel, stick a socket larger than the cap on top and press or hammer down on the socket. The result is to force the whole u-joint upwards, and the upper cap comes out into the socket on top. Flip it over and repeat to push the other cap out. There is no force trying to bend the ears using this method. The typical method people use of pressing everything downwards risks the upper cap sticking and bending the upper ear inwards.

 

Don't we all wish we had a full workshop of tools and a clean space to work when the driveshaft falls out on a steep mud covered incline.... 👍👍

 

True. The deep-woods, improvised redneck repairs can be pretty challenging (and sometime quite ingenious in my experience). Doesn't mean you can refine your technique where possible to minimize damage.