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Transfer Case & Ujoint Troubles

Discussion in 'Flat Fender Tech' started by Buster1, Aug 8, 2021.

  1. Aug 8, 2021
    Buster1

    Buster1 New Member

    Ft Worth
    Joined:
    Aug 8, 2021
    Messages:
    49
    Hi guys. First post (after my intro post) and wondering if there is any advice out there.

    I’ve had two issues come up as I’ve been pulling, cleaning, and refreshing my front drivetrain.

    1. Pulled the oil bearing output seal off of the front of the transfer case and found the below. Looks like part of the thin metal flange the oil seal rides on is gone. The bearings and spline turn and move great! No issues there. I’m thinking of just putting the new double lipped seal in and rolling with it. Thoughts?

    0256A318-086C-4DB8-B920-DF242A949DE8.jpeg

    2. We got the new U Joint in on one side, but the front end ear holes are incredibly ovaled and out of round. The new caps won’t press in straight, and keep binding and diving off. I think it’s time for a new driveshaft. My press tool is great, but I can’t get those caps straight at all. Now they’re jammed too.

    B9486A10-71EF-4FAE-88E7-9A6B8D96A687.jpeg

    Thanks for any tips or advice.
     
  2. Aug 8, 2021
    oldtime

    oldtime oldtime

    St. Charles,...
    Joined:
    Aug 14, 2006
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    3,466
    1) It’s fairly common to see part of this bearing and seal face to be broken off.
    Install a good seal with some permatex and call it good.
    2) If ovalled out which is not common, then it’s time to locate a replacement part.
     
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  3. Aug 8, 2021
    Buster1

    Buster1 New Member

    Ft Worth
    Joined:
    Aug 8, 2021
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    Thank you!
     
    ojgrsoi likes this.
  4. Aug 12, 2021
    OnlyOneDR

    OnlyOneDR Member 2023 Sponsor

    R
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    I had an issue one time where I was helping a friend refresh his rear driveline and replacing his u-joints. He had a yoke that was tweaked like yours (looks like one ear is bent in somewhat). I carefully wedged it in a vice, put a plate of steel against the inside of the bent ear, and used a heavy bolt through the hole of the other ear and beat on it with a hammer to bend the ear back straight. Do not use heat, just cold work it.

    As far as getting the yoke back out just be careful with some wood and a hammer (or a soft-faced dead blow hammer) and you may be able to beat it back loose. I would set the end that is deeper pointed down and beat on the cross to push that one back out then get the cross inserted into the other cup and push it out using the same method.

    Once you get it all apart you can always lightly dress the openings with a die grinder to allow the cups to set in the hole a little deeper. Not sure what you are using to press the cups in; many times you can use a bench vice to work them in slowly. Don't use a socket and a hammer; that is asking for trouble. A hydraulic press is nice but can also get you in trouble in a hurry if the cups skew crooked. You can easily bend the ears with a press.
     
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  5. Aug 13, 2021
    duffer

    duffer Rodent Power

    Bozeman, MT
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    Sep 17, 2009
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    4,460
    Yes, one can do that. But the probability of getting the axial alignment back to the factory spec, which is likely something close to .001-.002 is essentially zero and the service life of the new u-joint will likely be short. If the installation is in a Jeep that sees few miles perhaps it will not make much difference. On the other hand, if the rig is a daily driver, I think tweaking a yoke is a recipe for a lot of problems, including loosing one of the ears from a stress crack. In short, not something I would do.
     
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  6. Aug 20, 2021
    Oldpappy

    Oldpappy A.C. Fults - Curmudgeon at large 2022 Sponsor

    East Tennessee
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    Feb 8, 2021
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    1,620
    I would look for a new drive shaft, there are plenty of them out there. If you can't find one local to you, I probably have a few laying around.
     
  7. Aug 21, 2021
    jeeper50

    jeeper50 jeeps 'till I die

    Spanish Fort. AL
    Joined:
    Dec 20, 2007
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    844
    Looks like the one cap is driven in a bit cockeyed and that is causing your new ujoint not aligning with the other cap. Just $.02 Straighten it up and I bet it slips right in just make sure all the needle bearing are present.
    If not I have an extra front and rear driveshaft from an ECJ5,
     
  8. Aug 21, 2021
    Buster1

    Buster1 New Member

    Ft Worth
    Joined:
    Aug 8, 2021
    Messages:
    49
    Thanks guys!

    UPDATE: I was able to get the whole u joint apart and freed from the yoke ears! Lots of swearing and careful application of pressure with my press and impact, got it freed.

    Then, I re-attempted assembly, but went slower and pressed one cap in straight almost all the way. This allowed for better alignment of the opposite cap, and again with lots of careful and incremental slow pressing I got both caps seated with no jams and verified needle bearings good!

    I’m gonna give it a shot in the Jeep!

    Thanks again!
     
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  9. Aug 23, 2021
    OnlyOneDR

    OnlyOneDR Member 2023 Sponsor

    R
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    Good deal. Perseverance wins the day.
     
    Buster1 likes this.
  10. Aug 23, 2021
    Oldpappy

    Oldpappy A.C. Fults - Curmudgeon at large 2022 Sponsor

    East Tennessee
    Joined:
    Feb 8, 2021
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    1,620
    They can be tricky. I usually pull on cap off, swing in the joint into the yoke, put the pulled cap back on the shaft which will be sticking up so it can go on, and then press it in.

    The thing I have found that helps a lot is to clean the inside of the yoke well, run a brake hone in it a bit, clean it again and oil it.
     
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