Assembly Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. 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 the trunnion seats freely into the bearing cup.

Fig 1: Assembling Trunnion Into Yoke

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.
Assemble the opposite bearing cup part way into the yoke ear.

Fig 2: Installing Bearing Cup Into Yoke Ear

Courtesy of GENERAL MOTORS CORP.

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 a free unbinding movement of the trunnions in the bearing cups.

IMPORTANT: If there seems to be a hangup or binding, stop pressing, and inspect the needle bearings for misalignment in the bearing cup.

Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke.
Assemble the bearing retainer in the retainer groove.

Fig 3: Assembling Bearing Retainer In Retainer Groove

Courtesy of GENERAL MOTORS CORP.

Continue pressing until you can snap both retainers into place.
If seating the retainer is difficult, spring the yoke slightly with a firm blow from a dead blow hammer.

Fig 4: Springing Yoke Using Hammer

Courtesy of GENERAL MOTORS CORP.

It may be necessary to lubricate the snap ring with a slight amount of chassis grease so the snap ring seats in the bearing cup groove.