So after replacing the stripped out coupler in my transfer case, I found that my front shaft u joints were getting pretty loose (OK, a LOT loose... ), so I figured I would rebuild it.

I got Ujoints from NAPA and pressure washed the thing off and immediately ran into a puzzling question. The new ujoints are like most u joints are, retained by c-clips on the inside of the yoke. however, the ujoints on my driveshaft aren't retained by clips, there aren't any there, but instead, these little plastic plugs. I tried to pry one loose with the pocketknife and the top of it shaved off, but there is still plastic underneath.

What is the function of these things and do I need to remove them before driving out the old ujoint? And it looks like I got the wrong kind of ujoints from NAPA, but there wasn't multiple choices, only these...presumably I would need new little plastic bits too.

??

My NAPA guy must be getting sick of my truck, nothing is ever the way his parts book says it should be...

 

Those are the factory u-joints. The factory held them in by injecting plastic through those holes. The cap is grooved as well as the yoke. Just press them out, there's a groove in there for the c-clip once you clean the plastic out.

 

C-clips were just too expensive, huh?

Well, it is impressive I guess that the factory ujoints made it to 265k and that the little plastic bits held it together the whole way...

thanks, I really didn't want to face the NAPA guy again...

 

Well, it is a press fit. The c-clip/plastic ring is only for insurance.

 

When I needed to do the U joints on my son's truck, which are the same factory junk, it helped greatly to heat the caps with a MAPP torch to melt the plastic. I needed to do this because I could not hit the caps hard enough with the hammer to move them after I broke my vise trying to press them out.

 

You can try my method but it stinks. Grab your torch, then heat em & beat em.

 

Ahh, I have a little press, so it shouldn't be a big deal.

I paid $20 for the press at a garage sale, and I haven't used it much, but when I've needed it, it was invaluable...