2nd Gen Non-Engine/Transmission U-joints loose in axleshaft

[RLHannink]

This is the second time the u-joint cups have gotten loose in the right side axleshaft. Is this a common thing to happen? The truck has close to 260K on it, some pretty hard off road use especially in the last year. I replaced the stub (outer) shaft with a used one when a cup got loose the first time, now a cup is loose on the inner shaft. I have another used inner axleshaft, but was wondering if there is an aftermarket replacement that will hold up better. I have new Napa u-joints, and the wheel bearing assemblies are also only a month old. (Sick of taking the front axle apart on my days off)

 

[MKinner]

Have you tried a different brand u-joint? sometimes a different brand than what was originally in there will be just a thousandth smaller or so and cause a loose fit. I hear the spicer joints are nice...

 

[JoeBioDiesel]

I use a quality waterproof grease (Mobil Synthetic) and I grease them every 5000 miles, more if I'm offroading and getting water in them. Today I will roll 300K miles on my truck and the last time I changed them was at about 160K. They are NAPA brand.

Joe

 

[RLHannink]

I talked to a driveline shop guy today, he didn't have a replacement inner shaft but said it'd probably work just fine to tack weld the cup to the yoke to prevent it from rotating and eventually failing due to snap ring coming out. He also said that some drag racers have him weld the cups to the yoke on new driveshafts so they won't rotate. I think I'll try it, alot cheaper than 279 bucks and 2 hours of taking the axle apart (again). Has anyone else tried this? (and had it work out well for them?)

 

[Joseph Donnelly]

Check the dimensions of the cups and the holes in the front axle shafts with micrometers. The axles may have stretched the holes, in which case they should be replaced. DO NOT weld as the stress risers could cause failure and also will destroy heat treat of the u-joint cups as well as carbonizing the grease inside. If you feel you just have to do something, use green 609 Loctite to retain the cups better to the axles.

 

[RLHannink]

Well, about 3 weeks ago (before I read the previous post) I tack welded the cup to the yoke (actually had cousin do it). Put some very small tacks around the cup, probably could tap them off easily with a chisel. So far, after putting some pretty good power through the front axle, so good. No rotation of the u-joint cup, no cracks in the yoke or anything. Greased it up right after we welded it, put enough grease into it to force some out of the seal, looked ok.