Hello and thank you in advance for any and all help you may be able to give.
I have been replacing the clutch in my truck now for a month and slowly taking my time and due to my health I have to work in short spurts. I am just a couple hours away from firing it up for the maiden voyage but I cant get the front drive shaft to go back in properly. I am using red tacky grease to help hold the stuff in place while alignment but it just doesn't fit like I think it should.
I know the ***** fit in the ring making a bearing. I know to grease it all before trying to install.
I need to know, Whats the proper steps to get it back together in the transfer case?
I tried putting it together on the driveshaft, then sliding it in the transfer case hub. That didn't work. I then tried to put the ball bearings and the race into the transfer case hub and slide the drive shaft into it, that didn't work... Help?


OK, Someone just told me the JOINT came apart and I didn't take the whole HEAD out of the transfer case. NOW WHAT?
How do I get it all back together?

 

Im starting to think my computer doesn't post on this site. Or no one ever comes here and replies......

 

Nevermind, I got it put back together. I just welded the ***** to the race and then welded the unit to the shaft....

 

Plenty of people are reading your post, it's just that no one knows the answer...

 

I hope that was a joke to see if anyone was paying attention. It's a CV joint so those ***** can't be tacked in place.

 

LOL, it was. see next post...

 

Ok, FINNALLY got the cvc joint put back together. Its a jigsaw puzzle and it has to look exactly like my photos show it. Its a very tight machine fit and you have to use a press to "pop" it back together. And yes, it actually popped.
Place flat side of housing down, put ***** into race lining them up with the grooves of the housing, then set the splined shaft holder into the ***** making sure the smaller pointy outer edges are lined up opposite of the larger outer parts of the housing. Using a press, push the splined part into the ***** and race and housing part just a little bit, enough to hold it all together well. Then flip entire unit over and using a flat piece of steel against the housing, press the housing downward over the ***** and splined part. It will get to the stage where it "breaks over" the tightness of machining and pop into place. I then had a perfect CVC joint once again..... and know not to ever do that again..... I drove the truck 20 plus miles this afternoon in and out of 4x4 and it's perfect. Btw, Don't forget to grease it with tacky red grease before installing again..

 

Looks like those $149 Horror Freight 20 ton presses actually are good for something....
I kid, I kid. I have one myself.

 

It's like a large set of bolt cutters, it comes in handy about once every two years.... but when you need it, it's a life saver. A new CVC joint was going to cost like $60.

 

Drove my Ranger all week and we had a snow storm requiring 4 wheel drive to and from work twice, a total of 40+ miles. Everything is normal and working great. Maybe I am just posting to myself but just incase you have the same issue as I did, maybe it'll help, Thanks.