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Driveshaft Universal Joint: Assembly

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Universal joint service kits are to be installed as complete assemblies only. Do not use components from other universal joints.
  1. Install a new bearing cup.
    1. Start a new bearing cup into the driveshaft yoke.
    2. Position a new spider in the driveshaft yoke.
    3. Install the driveshaft into the U-Joint Tool.
    4. Press the bearing cup below the yoke surface.
      Fig 1: Installing Bearing Cup
      G04582847Courtesy of FORD MOTOR CO.
    2. NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing the yellow snap rings, install the black snap rings also supplied in the kit.
    Fig 2: Installing Snap Ring
    G04582848Courtesy of FORD MOTOR CO.
  2. Remove the driveshaft from the U-Joint Tool and install the snap ring.
  3. Repeat Steps  1 and  2 for the opposite side.
  4. Install a new bearing cup.
    1. Start a new bearing cup into the driveshaft centering socket yoke.
    2. Install the driveshaft into the U-Joint Tool.
    3. Press the bearing cup below the yoke surface.
      Fig 3: Installing Bearing Cup
      G04582849Courtesy of FORD MOTOR CO.
    5. NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing the yellow snap rings, install the black snap rings also supplied in the kit.
    Fig 4: Installing Snap Ring
    G04582850Courtesy of FORD MOTOR CO.
  5. Remove the driveshaft from the U-Joint Tool and install the snap ring.
  6. Repeat Steps  4 and  5 for the opposite side.
    7. NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer.
    Fig 5: Checking Universal Joint Operation
    G04582851Courtesy of FORD MOTOR CO.
  7. Check the universal joint for freedom of movement.
  8. Install a new bearing cup.
    1. Start a new bearing cup into the driveshaft yoke.
    2. Position a new spider in the driveshaft yoke.
    3. Install the driveshaft into the U-Joint Tool.
    4. Press the bearing cup 6.3 mm (0.25 in) below the yoke surface.
      Fig 6: Installing Bearing Cup
      G04582852Courtesy of FORD MOTOR CO.
    9. NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing the yellow snap rings, install the black snap rings also supplied in the kit.
    Fig 7: Installing Snap Ring
    G04582853Courtesy of FORD MOTOR CO.
  9. Remove the driveshaft from the U-Joint Tool and install the snap ring.
  10. Repeat Steps  8 and  9 for the opposite side.
  11. Install a new bearing cup.
    1. Start a new bearing cup into the driveshaft slip-yoke.
    2. Install the driveshaft into the U-Joint Tool.
    3. Press the bearing cup 6.3 mm (0.25 in) below the yoke surface.
      Fig 8: Installing Bearing Cup
      G04582854Courtesy of FORD MOTOR CO.
    12. NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing the yellow snap rings, install the black snap rings also supplied in the kit.
    Fig 9: Locating Snap Rings
    G03912453Courtesy of FORD MOTOR CO.
  12. Remove the driveshaft from the U-Joint Tool and install the snap ring.
  13. Repeat Steps  11 and  12 for the opposite side.
    14. NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer to seat the bearing cups.
    Fig 10: Checking Universal Joint
    G04582856Courtesy of FORD MOTOR CO.
  14. Check the universal joint for freedom of movement.
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