Busted U-Joint

[F-15I Ra'am]

One of the u-joints on the 4wd driveshaft has a busted cup. Whats the removal procedure for the front driveshaft? Anyone with a manual please post or send me a scan of it. Truck is a 2004. Thanks!

 

[rbattelle]

One of the u-joints on the 4wd driveshaft has a busted cup. Whats the removal procedure for the front driveshaft? Anyone with a manual please post or send me a scan of it. Truck is a 2004. Thanks!

No need for a manual, should be a piece of cake. 4 T40 Torx bits at the axle flange, and 4 hex bolts at the transfer case flange. Just take 'em out!



Only problem is getting a T40 Torx socket that will fit without interfering with the front u-joint assembly. I bought a long-reach (5") T40 bit from McMaster-Carr. I'm not sure how others have been doing it... no one except me and HOBrian has ever complained about it.



Thank God HOBrian noticed it and asked me about it, or I'd be up the creek if I had needed to remove my front driveshaft!



-Ryan

 

[F-15I Ra'am]

I had removed the 4 hex bolts at the t-case and hit it some with a hammer {not enough obviously } just wanted to make sure there was nothing else holding it. The front torx bolts I figure {hope} I can move the drive shaft enough,once the back is disconnected, to get the torx socket in there? Called the dealer. Parts guy said he needed my v. i. n. # {said there were 5 different driveshafts for the 3500 and they might not interchange} cost would be $225 and they're on backorder! Cost for one u-joint is $91. Looks like just the 2nd one from the t-case is bad. I'll either get all three from NAPA, anyone know the part#s ? Or if I can get out to Albuquerque, have a driveline shop rebuild it.

 

[rbattelle]

I think a Precision #464 joint will fit in the front shaft... . (based on reporting from other threads).



-Ryan

 

[Slow Six]

I just finished all the u-joints on the front shaft. I had trouble with one of the Torx bolts. Ended up drilling it for an easy out and then the head twisted off. Once the yoke was off I turned it out with vise grips. I got the right size hex head bolts and some grade 8 washers to replace the Torx bolts. They are slow to tighten up but now I can use a real wrench. I am not sure of the part numbers. I used Precision greasables. Two joints are the same and the one at the diff is a different number. I still have the boxes in the shop. If you want the numbers let me know and I'll get them in the morning. If you strip out a Torx they are easy to drill. I couldn't believe how soft they were. I also removed the skid plate for easier access to the rear bolts.

 

[jwilliams3]

The 464 is for the front axle shaft joints.



There are 2 different u joints for each front drive shaft.



2 of 1 and 1 other.

 

[JStieger]

I got the right size hex head bolts and some grade 8 washers to replace the Torx bolts. They are slow to tighten up but now I can use a real wrench. I am not sure of the part numbers.

I did the same thing on mine after almost stripping the Torx head on one bolt!



As far as accessing the bolts I just jacked up and supported one of the front tires off the ground and then spun the wheel while I was underneath to access each bolt from underneath. I also used the Precision greasable joints - maybe $60 for all three - and then took them into a driveline shop who charged $50 to press the old ones out and install the new ones.

 

[F-15I Ra'am]

Thanks for all the help guys! Just finished taking it off. Luckily Santa Fe Tool in Albuquerque had some extra long {6"} T-40 torx bits. Piece of cake with the right tools. Driveline shop quoted about $150 to rebuild it. I'll run it in Monday.