Dana 35 center u-joint replacement ??

[dennis461]

I've been searching for a few days and can't find it.
I thought someone wrote up how to replace the Dana 35 center u-joint with a special tool (instead of removing the passenger side axle).

Anyone done this without removing axles?

 

[Sasquatch_Ryda]

I've done it at work a couple times without removing the diff from the truck. Basically you cut the trunnion (the middle cross of the u joint) out with a torch and then remove the caps with hammer and drift. Its kinda a tricky and a bit of a PITA but it can be done. Its much nicer to just pull the diff and do it on the bench.

 

[dennis461]

Well, first plan did not work.
Used a propane torch to heat up the ears and an air hammer to beat on the cups.

Looks like I'll be going for the c-clip eliminator.
That pinch bolt looks like trouble.
I read where someone notched the control arm to the bolt out instead of removing the control arm.

 

[Sasquatch_Ryda]

I notched the head of the bolt so it would just slide past the radius arm on mine. The head of the bolt is now a D shape.

 

[Hahnsb2]

I'd rather drop the beam, I can have the beam on the ground and pig separated in an hour on a good day.. It's not that bad of a job. I recommend heating the threaded "bosses" with a propane torch that the RA arm bolts thread into and with a big ass wrench or 2 you can loosen the bolts a bit and swing the RA out of the way.

 

[Will]

Better to get rid of the E-clip and put a spring around the shaft. Dropping the beam isn't neccesary to get the pig out of there, but it's a lot of work to take it out just to service a joint. That's the one most likely to break if you haven't clearanced the yoke and ground out your beam window. Pulling the pig out on the trail is not too pleasant and getting mud and stuff in there is a worry.