Assembly Procedure

WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.

Remove the bearing cups from the universal joint.
Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the bottom.
Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup.

Fig 1: Removing Bearing Cups From Universal Joint
Courtesy of GENERAL MOTORS CORP.
With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear.
Install the opposite bearing cup part way into the yoke ear.
Ensure that the trunnions start straight and true into both bearing cups.
Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups.
Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup.
Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup.

Fig 2: Pressing Opposite Bearing Cup Into Yoke Ear
Courtesy of GENERAL MOTORS CORP.
Assemble the bearing retainer in the retainer groove.
Continue pressing until both retainers can be snapped into place.

Fig 3: Assembling Bearing Retainer In Retainer Groove
Courtesy of GENERAL MOTORS CORP.
If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead blow hammer.
It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove.

Fig 4: Checking Yoke Position With Hammer
Courtesy of GENERAL MOTORS CORP.