Need help Front U-joint assembly.

[FishermanFred2]

Hello Guys Im new to the site but I sure like it. I have a 1991 Jeep Cherokee 4.0L I have been having different problemswith it turnning off as I drive down the hwy. but I thinkI have solved that problem. Now I have a new problem,the front U-joints on both wheels are making a constant clicking noise as I drive down the road (even in 2 wheel dr). I checked under the front end and found about ,one eighth inch movement in each U-joint . So by that you can see that they need replaceing. Now the big question to you ,can it be done without removing the hub and axleshaft? Thanks for looking at my question and please leave advice and instructions for me to make this repair. Also am I doing the right thing in replaceing the U-joints only,or is it normal repair to replace the entire axle? Again thanks for your answer. Fred[addsig]

[MudderChuck]

I´ve done this job more than a few times. And I still thumb through the manual before starting. Most of these peices are just to darned expensive, to be taking chances on breaking one thing while, trying to fix another.

If you havn´t got the book, try getting a Chiltons from the library.

Just replaceing the front (prop shaft) axle shaft U-joints is pretty normal stuff for Jeep. I can give you a couple of tips that might not be in the book.

The right side has a gizmo to shift the right axle in and out, located on the rear right side of the axle housing. When removing remove slowly so you can see where the shifting fork is supposed to go, it can be replaced wrong. And the photos in the manual ratley show this in detail. Don´t worry about a gasket, just thoroughly clean and seal with silicon.

Loosen the large middle nut with the tires on the ground.

If you lift one side at a time (high) you will loose very little differential oil.

When removing the front breaks, don´t let them hang by the break lines as this will cause them to crack, use a bit of wire to tie them up out of the way.

If the bearing houseing hasn´t been off for awhile, it can be a pain. It´s probably rusted to the steering knuckle. Beating on it with a hammer rarley helps but a little tap, tap, tap well away from the bolt holes and some penetrating oil can be helpful. If all else fails use a sharp cold chisel, and hammer with feeling (not to much not to little) between the bearing houseing and the knuckle (well away from the bolt holes). If the two peices become a little notched they can be filed straight againg, with no adverse affects. When trying to beat everything loose, try a little on all three sides, these peices can become wedged.

I wouldn´t even attemp changing the U-joints themselves without a bench vise (large). And a couple of sockets, one about the same size as the bearing cap and one with the inside a little bigger than the bearing cap, to push against in the vise.

The U-joint bearing cap C clips can be a pain try spinning them a little with a hammer a screw driver before trying to remove them. A little thin oil helps also.

When buying replacement U-joints, try and get them with zirk fittings, this will really help with longevity.

Lastly generously covering everything with a good coat of white grease will help in getting everything apart next time.[addsig]