How to Change a U-Joint on a Dana 44

A Dana 44 is a type of heavy-duty axle and rear end assembly that can be found in most automotive manufacturers' vehicles. Over time, the bearings inside of the u-joint caps can freeze up and prevent the u-joint from turning properly. The u-joint that attaches to the yoke on the Dana 44's rear end comes with an inner half-moon clip below the u-joint caps instead of the outer snap rings above the u-joint caps. Replace the u-joints at the first sign of looseness, slack or any damage to the u-joint caps.

Instructions

1

Park the vehicle on a flat surface and set the parking brake. Place wheel chocks in front of and behind both front wheels.

2

Slide under the rear of the vehicle and locate the drive shaft yoke that is attached to the yoke on the Dana 44's rear end assembly. The u-joint attaches both of the yokes to each other. Mark the top of the rear drive shaft yoke and the rear end yoke with a piece of chalk.

3

Loosen and remove the four u-joint strap bolts from the drive shaft yoke with a ratchet and socket. Set the bolts and the straps aside. Pull back on the end of the drive shaft until the u-joint is out of the rear end yoke. Use a hand-held sledgehammer to tap the top of the drive shaft back until the u-joint is out of the rear end yoke. Place the end of the drive shaft on the ground.

4

Grab the yoke attached to the rear of the drive shaft and pull the shaft out of the primary drive shaft. Slide the rear drive shaft out from under the vehicle. Place the yoke end of the drive shaft into a vise. Tighten the vise around the yoke.

5

Pry the half-moon clips off of the bottom of the u-joint caps. Place the tip of a flat head screwdriver against one of the clips. Tap the end of the screwdriver until the clip pops out of the groove below the cap. Repeat this for the other three u-joint cap clips.

6

Loosen the vise and position the yoke inside of the vise so that one of the u-joint caps is facing up and the other cap is facing down. Tighten the vise around the yoke. Place the end of a deep-well socket that is one size smaller than the u-joint caps over the top cap. Tap the top of the socket with the sledgehammer until the bottom cap slides off of the end of the u-joint. Finish removing the bottom cap with a pair of pliers, if necessary, by turning the cap back and forth until it is off of the u-joint.

7

Loosen the vise and turn the yoke over so that the exposed half of the u-joint is facing down and the bottom cap is now facing up. Place the deep-well socket over the top cap. Tap the socket with the sledgehammer until the bottom cap slides off of the u-joint. Use the pliers if necessary. Loosen the vise and repeat this process for the remaining two u-joint caps.

8

Wipe out the holes inside of the drive shaft yoke with a clean shop rag. Position the new u-joint inside of the drive shaft yoke. Place a new cap over each end of the u-joint that is inside of the drive shaft yoke. Tap the caps onto the ends of the u-joint with the sledgehammer until the caps are fully secured to the u-joint. Leave the other two caps off of the u-joint until it is ready to be installed onto the rear end yoke. Insert a new half-moon clip around the bottom of each u-joint. Use the sledgehammer, if necessary, to tap the clips around the bottom of the caps.

9

Slide the rear section of the drive shaft underneath the vehicle. Slide the splined end of the drive shaft into the primary drive shaft. Carefully place the other two u-joint caps over the two remaining ends of the u-joint. Pick up the rear drive shaft yoke and position the new u-joint inside of the rear end yoke. Ensure that both chalk marks match up with one another.

10

Place the u-joint straps over the drive shaft yoke. Screw the strap bolts into the yoke until they are tight. Use the ratchet and socket to finish tightening the bolts. Torque the strap bolts down to 35 foot-pounds with a torque wrench and a socket.

11

Pull the wheel chocks out from the front wheels. Drive the vehicle around for about 10 minutes then park it and turn the engine off. Set the parking brake again.

12

Recheck the torque on the strap bolts to ensure that all four bolts remain at around 35 foot-pounds. Re-torque the strap bolts if necessary.