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Double CARDAN Universal Joints: Assembly

WARNING: This page is about a different car, the 2002 Ford Pickup, 2002 Ford F550 Super Duty, 2002 Ford F450 Super Duty, 2002 Ford Excursion, and 2002 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the "U" joint in the drive shaft end yoke, and position the "U" joint bearing cup on the "U" joint trunnion. Using the "C" Frame and Screw Installer/Remover (205-086, T74P-4635-C), press the "U" joint bearing cup far enough into the drive shaft end yoke to place the opposite "U" joint bearing cup on the "U" joint trunnion. See Fig 1.
  2. Position the opposite "U" joint bearing cup on the "U" joint trunnion. Using the "C" frame and screw installer/remover, press the "U" joint bearing cup to just below the snap ring groove. Install the NEW snap ring. See Figure.
  3. Using the "C" frame and screw installer/remover, press the opposite "U" joint bearing cup to just below the snap ring groove. Install the NEW snap ring. Align the index marks made during disassembly and position the drive shaft center yoke on the "U" joint.
  4. Using the "C" frame and screw installer/remover, press the "U" joint bearing cups into position. Install the snap rings. Apply Premium Long-Life Grease (XG-1-C) to flange. See Fig 2.
  5. On the one-piece rear drive shaft, install a NEW centering cup spring. See Fig 3. Align the index marks made during disassembly and position the remaining "U" joint, the centering flange yoke, and the "U" joint bearing cup.
  6. Using the "C" frame and screw installer/remover, press the "U" joint bearing cup far enough into the yoke to place the opposite "U" joint bearing cup on the "U" joint trunnion. Position the opposite "U" joint bearing cup on the "U" joint trunnion.
  7. Using the "C" frame and screw installer/remover, press the "U" joint bearing cup to just below the snap ring groove. Install the snap ring. Using the "C" frame and screw installer/remover, press the opposite "U" joint bearing cup to just below the snap ring groove.
  8. Install the snap ring. Position the "U" joint bearing cup on the "U" joint trunnion in the centering flange yoke. Using the "C" frame and screw installer/remover, press the "U" joint bearing cup into position.
    9. CAUTION: The assembly requires centering to install the final "U" joint bearing cup, due to spring pressure.
  9. Position the jaws of the Differential Bearing Remover (205-116, T77F-4220-B1), into the drive shaft center yoke "U" joint bearing cup bores. With the differential bearing remover and Step Plate (205-D014, D80L-630-3) in position, hand-tighten the differential bearing remover to center the "U" joint trunnion in the bore. See Fig 4.
  10. Using the "C" frame and screw installer/remover, install the final "U" joint bearing cup. See Fig 5. Remove the differential bearing remover and step plate. If necessary, tap the yokes with a soft-faced hammer to seat the "U" joint bearing cups.
  11. Install the remaining snap rings. Move the end yoke through the working angles to verify freedom of movement.
Fig 1: Identifying "U" Joint Bearing Cup
G00199314Courtesy of FORD MOTOR CO.
Fig 2: Identifying Lubrication Point On Flange
G00199315Courtesy of FORD MOTOR CO.
Fig 3: Removing & Installing Center Cup Spring
G00196629Courtesy of FORD MOTOR CO.
Fig 4: Centering Bearing Cup Bores
G00199316Courtesy of FORD MOTOR CO.
Fig 5: Installing Final "U" Joint Bearing Cup
G00199317Courtesy of FORD MOTOR CO.
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