I'm working on my '91 W250 w/ the NP 205 t-case and have ran into problems. The u-joints I ordered do not fit (too wide) because u don't have room to snap the clips into place on the inside of the yoke. You can get one side in but not have room for the other. The Spicer #s I used was 5-789x (front) and 5-795x (rear). I crossed these numbers over to the following Precision #s 315G (front) and 534G (rear) and they don't fit. Any help or info is appreciated.

 

You have a single rear u-joint and not a double cardan?

 

No. I DO have the cardan joint. I guess I didn't explain that good enough. There is supposed to be 2 of the 534G u-joints to use on the cardan joint and the other u-joint is for the front. So, yes I have 3 u-joints in the front driveline.

 

And all three dont fit??

 

There is also a spring kit that you need for the double cardan joint, rockauto has it...Mark

 

I'm also rebuilding my front drive shaft. The axle end u-joint should be a spicer 7260/ Precision 317. The double Cardan joint should be Precision 534G.
Is there a possibility that you have an after market replacement shaft on your truck?
Is the second grove close to being in the right place but not quite there or is it way off?
I've had them be real freakin' close but not quite there before and had to tap the retainer clip in with a punch and hammer. I had a jeep axle that I had a heck of a time getting the ujoint out of. When I put the new joint in there wasn't space for the retainer clip on one side. Turns out that, between beating on it with a hammer and vice and too much application of the heat wrench I bent the axle ear. Figured it out by measuring the space between ears on the axle and the stub shaft. Axle ears were like a 16th of an inch closer. OOPS!! Luck I had a few more sitting around.

 

Oh... almost forgot. I had a needle bearing drop between the cap and the end of the cross once that caused the retainer clip groove to not line up properly. You might want to check that too.

 

We figured it out. Turns out the mechanic didn't want to mess up any ujoints he thought didn't fit. He had just eyeballed the joints and hadn't tried to make them fit. We got them in there and they are the right ones. Either 315G or 317 for front and 534G for the rear.

Thanks

 

Wow. Time to find another mechanic. Or, DIY like you just did.

 

I've had both of these experiences as well.
I beat the ear back some to vet the clip in and ran it.
When I got the needle stuck under the cap I was using a ball joint press and I actually cracked the cap! Costly mistake but I learned something.

 

Was this DO'LESS & SEEMORE automotive?

 

lol!

 

I thought it was Dolittle & Seymor Auto. Right next door to the Dewey, Cheatem & Howe Law firm.