Rust welded U-joint bearing caps

[blasphemous]

I picked up a Dan 60 front about 6 months ago. It's in need of a total rebuild, so I recently had the money to buy all the parts I needed and get to work on it. I got the hubs, brakes and spindles all disassembled and cleaned up. Then pulled the axles to remove the old U-joints.
Well, I did as I read on the internet and set the axle in my vise and beat on the correct area. The end of the caps would pop/break off, but the "neck" part of the cap stayed in the ears on the shaft. Is there a secret or trick to getting the rest of the caps to come out of the ears?

 

[JEBSR]

Did you remove the retaining clips prior to trying to remove the caps? If it has internal clips they can be difficult to see when dirty. If you removed them and still can't get them out the way you are trying, you will most likely have to use a press.

 

[blasphemous]

Did you remove the retaining clips prior to trying to remove the caps? If it has internal clips they can be difficult to see when dirty. If you removed them and still can't get them out the way you are trying, you will most likely have to use a press.

I used a wire brush to clean the area, but I didn't see clips anywhere. I forgot to mention that part. That is, unless they're rusted in so bad the look like part of the ear now?

 

[lectric80]

That is most likely the case, as they are inside the ears. There are definitely some c-clips that are there, and that is what is holding those caps in.

 

[JEBSR]

There are "C" clips that go around the U-joint cap on the inside portion of the yoke. Once you see it, you can move it with a screwdriver into a position where you can remove them and then the caps will come out.

 

[sweetk30]

you can cut out the old ujoint cross and then drive the caps out and in to the center if need be. its rare but i have had to do this before up here in the rust belt.

when all done and ready to install new. take a file and clean the clip area smoth and flat to help make the clip go in better on the new caps.

 

[blasphemous]

you can cut out the old ujoint cross and then drive the caps out and in to the center if need be. its rare but i have had to do this before up here in the rust belt.

when all done and ready to install new. take a file and clean the clip area smoth and flat to help make the clip go in better on the new caps.

I may have to do that... when I say rust welded, I mean when I got it, it all looked like one big glob of metal. I think this thing had a salt water bath for about 15 years. It's going to be a brand new asle by the time it's over though.

 

[JEBSR]

Here is an illistrated guide. Not for your application, but this type all work the same. Click on the pics to enlarge them. You will see where the clips are (and how easy it is to overlook them) in the first picture.

http://www.supermotors.net/vehicles/registry/139/13251

 

[sweetk30]

if you use any form of pressing them be vary carfull as i have seen yokes bend and then clips wont go on and wose thay eat ujoints up quickly as its now bent.

 

[blasphemous]

Well, as suspected, the clips were in a rust ring and blended into the yoke. I used a sludge and a chisel to knock them lose. That didn't make it much easier. I still could only pound out the caps about 1/2 way, then cut them off with a cutoff wheel.

 

[Mudstud]

You won't be able to push the caps all the way out. I use some RoboGrips or vice grips to grab them and twist them out. PB blaster is your friend. If your axle is in that bad of shape I'd squirt all hardware with PB blaster and start them soaking ASAP and each day hit them again. Careful not to twist the heads off the bolts holding the cover on.