chrgd you are correct there isnt a cotter pin in it

 

Just get the right u joints. If you modify they will not function long term.,Just because a "machine shop" pressed them in does not make them right.,I've owned a Tranny shop and a machine shop for 15 yrs, pls get the right ones.,God BlessJohn
The joints are "on all the way".

 

They are the right joints...neapco 297's

 

I pressed the U-joints myself using the following tool (free from O'Reillys):

KD Tools 3421 - Ball Joint Press | O'Reilly Auto Parts

It is a bit tricky and I ran into the needle bearing falling over problem. Just make sure that the cap is aligned properly before applying a bunch of pressure. I recommend wiggling the u-joint while you press in the cap to ensure that it remains free. If it starts to bind, back off and reset.

As for the cotter pin. I was still in the process of torquing everything to spec when I took those pics. Good looking out! Thanks for the heads up.

--JJ

 

I would just trying tapping them. As long as the clips are on, they shoud be on the inside of the ears. It should not take more than a light tap. If it is on the pass side it could be hung up on the rubber sleeve that covers the slip yoke. I just did my 86 Bronco yesterday, and needed a extra hand to line the joint up. I have bent the ears on axles using a press, then the fun starts try to bend them back. So now I just use my plasma cutter to cut out the cross of the u-joint, now I am ony driving out 1 cup at a time instead of 2.

 

I had a needle bearing that fell down and had the same problem,,but on both axis,,either the needle bearing fell or it is the wrong U joint,,,murphys law I guess,,

 

Yup, a ball joint press can be used to change them. A vice and some metal pipe (or big impact sockets) can also be used.

I remember changing driveshaft u-joints on my F-250 right on the tailgate... no vice, no balljoint press, just hand tools. I don't remember what I used to do it, but it had to be just basic hand tools since I didn't have anything else around.

As for the needle bearings falling over... take a nice plug of grease and smear it all over the rollers. Keeps 'em stuck to the inside of the cap so they don't fall over, or end up on your floor, under the workbench, in that pile of grinding dust you've been meaning to clean up.