Trouble With U-joint Fitting Through Steering Knuckle

Hi Guys—‘72 CJ5. Having trouble and wanted to stop and ask a question before doing anything dumb…

I am rebuilding entire front end. I just replaced ball joints and installed steering knuckle onto the yoke.

I have new u-joints on the axle shafts. I am fairly certain the cups are properly installed, and the clips fit correctly. The u-joint cups sit proud of the axle shaft yokes, and prevent me from fitting the assembled axle shaft through the steering knuckle.

Is this common? Am I ok to just grind off the cups where it interferes a little to get it to fit?

 

I'm assuming you've tried to rotate the joint 360 degrees and pushing inboard the whole time. That knuckle hole may not be perfectly round.
Is this condition on both driver's and passenger side?
What's a little?! A few thousands removal is probably OK. However, without knowing how thick those caps are, hand file only!
Is this a hard interference or can you tap the axle shaft past the knuckle with a soft hammer using a roughly 25 lb push?
I wouldn't be concerned about leaving a few scratches on the cast knuckle. You can smooth those out after the shaft is installed.

 

Those caps look proud to me. Try putting a c clamp across them and see if they move in slightly?

 

I have had to wiggle and jiggle the stub shaft in the past to get them to go through the knuckle. Those caps do appear to stick out slightly more than normal.

 

I Have had a similar problem when changing the joints, just used a C-clamp to squeeze them. There appeared there was a little hydraulic lock from the extra grease I had put in the caps.

 

+3 the caps look proud, I’d go with the clamps as previously suggested.

 

Thanks Guys—I tried squeezing them in a vice but didn’t budge. Not sure if they were just tall or hydraulic locked with too much grease. I measured them with calipers and it wasn’t as bad as I thought, just a few thousandths over. I lightly beveled the corners and got it in.
Got everything wrapped up this weekend and I’m back on the road after sitting for about a year.

had a little fun when I went to start it—turned the key, starter made one revolution, heard a loud POP, and fluid hitting the ground. Opened the hood, and the battery exploded…..so $200 battery as well.

my list this go round:
Steering column with improved bushing
Steering column bracket
Steering shaft (old one was welded)
Both steering shaft joints
New tie rod and drag link
Tie rod ends
Ball joints
Outer axle u-joints (old ones were rusted solid)
Inner and outer seals
Wheel bearings
Inner axle seals
Cleaned and greased cutlass lock outs
Sandblasted and painted as I went..

 

Are you sure one of the needle bearings didn't fall when you were putting things togther? That would prevent the bearing caps from seating fully.

 

Did you match new u-joint with old? I do this every time because some are put back in wrong box at vendor or they are just not quite right, maybe you were sold the wrong U-joint or it was mfg poorly.

 

X2. BTDT.

 

When I was young and working our parts counter, customer brought a pair of u-joints back claiming they were wrong.
Long story short, I removed the caps from both of them, and crushed needles were in caps on both.
Told him he just bought a pair of u-joints.

 

X3.. Just had that happen sunday on my ram 3500