U JOINT Question...

[Cityslicker]

I have to replace the U joint at the steering knuckle on my XJ, I CAN NOT get one of the C clips to pop off,, is there any good advice you can swing my way.. ALSO, I can't get the caps to budge. I have been smaking it with a socket and Sledge for hours. I'm bout to torch it. see if I can get some wiggle room. ANY advice would be very much appreciated.

[Metcalf]

Tough call. I would probably soak it in PB blaster or something for a few days.

I always tap the cap towards the middle or inside to help free up the clip a little bit.

A little heat wouldn't be a bad thing either since your going to replace the joint anyways.

[shortbus4x4]

The torch is your best friend when it comes to old rusty u-joints and their removal. I actually cut the cross section out so just the caps are left in the yoke, then a little PB Blaster and hammer and they usually come right out. No c-clip removal required for this method. Before I cut the cross section I burn a little hole in the top of each cap to let the hot expanding grease out, otherwise it can go boom and get hot grease all over.

[jagular7]

Try some PB Blaster on the caps to help loosen the rust weld.
To get the 'c-clip' out, you need to relieve the position of the cap by a little. The cap's location relative to the yoke is probably keeping enough pressure on the clip to keep it from coming out.

I like to use a vise or a-frame press when in the garage to change the joints. When in the field, I use the hammer/socket, but also another set of hands to hold the yoke perpendicular to the socket I'm hitting against. You need 2 sockets, 1 larger than the cap diameter, other smaller than the yoke. You pound the smaller socket to drive the opposite cap into the larger socket. If there is any kind of contact, the opposite cap won't budge.

[Cityslicker]

The torch is your best friend when it comes to old rusty u-joints and their removal. I actually cut the cross section out so just the caps are left in the yoke, then a little PB Blaster and hammer and they usually come right out. No c-clip removal required for this method. Before I cut the cross section I burn a little hole in the top of each cap to let the hot expanding grease out, otherwise it can go boom and get hot grease all over.

THIS IS GENIUS. I never thought to cut the thing out then pound the caps free.. this is why I posted this, I know this will work. cutting disc awaits!!!

[shortbus4x4]

THIS IS GENIUS. I never thought to cut the thing out then pound the caps free.. this is why I posted this, I know this will work. cutting disc awaits!!!

I am a flat rate tech so the faster I do a job the more I make. Never have used a cut off wheel to cut the cross section, do you have the room to do it? The heat from the cutting torch is a big part of why the caps come out so easy when I cut the cross section out. If all you have is a propane torch for heat, try heating the thinnest part of the yoke and then giving it some PB Blaster and a couple taps with a hammer before attempting to drive the caps out. If you have access to a parts house that rents tools out a balljoint press makes u-joint removal easy too. Just be careful how much force you put on it, I have seen the ears get bent from them and hydraulic presses.

[squint]

Harbor Freight has a nice tool that will pull it right out called a C-Press
I just picked one up today since I have a similar situation.