[tombob]

The problems mount with our '96 Cherokee.

I have previously posted about how difficult a time I was having removing the front axle u-joints and you guys repsondded with a generous sasortmetn of suggestions and encouragemnt. Many thanks, men.

Finally rented a ball joint press and exploded them out. Yes, exploded. I couldn't believe the torque that we had to put on that ball press screw. I guess those joints were rusted on. Even the needle bearing were in a sea of rust.

I guess we got a little to carried away with our inexperience. One of the outer yokes cracked. Can we have that welded, or that dicey? Or should it be replaced. None of the local auto parts stores carries any. I suppose that means a trip to the dealer?

Then, after assembling one of the new u-joints the shaft, one of the caps would not seat properly. to get it to go the last 32nd of an inch we poured on the torque and cracked the cap. Ruined the damn joint I guess. After removign the damaged new u-joint, I noticed the hole in the yoke where that cap seats was scored from the removal of the old joint. I guess that is why the new cap woudl not seat properly. Can I file it smooth and will it work with a new joint do you think?

Damn, but it is frustrating doing this stuff. Especially when everything is rusted on.

[RussoGuitar]

I would say go to a junkyard and pull an entire new axel shaft. Then, unless the joint looks new, replace it while the axels out. A lot of time new u joints will not have rounded caps like the stock ones and will stick out about a 32nd of an inch. As long as you can get the clips in then youre good.

[EricsXJ]

Adding to what was already suggested, there is no way to repair the cracked yoke. You will need a new shaft, but as the other poster said, it will be much easier to get a whole shaft assembly (inner + ujoint + outer) that is already put together. If you go the junkyard route or buy a used one from someone, make sure it has the larger u-joints that yours has. The older shafts with smaller u-joints will work too, but they are much weaker. Check the stock specs sticky for what year shafts to look for. Also any TJ shafts will work also.

PS. I've shattered a cap installing a new u-joint also!

[Meatroach]

Definitly a trip to the wrecker, Stay away from the dealer-stealer any time you can!

[tombob]

Do I have to replace the ENTIRE shaft--inner and outer? Can I just replace the outer stub axle?

Thanks for all the suggestions, guys.

[EricsXJ]

Yes you can just replace the outer stub shaft if thats the one with the cracked yoke. The disadvantage to doing that is you need to replace the u-joint which can be easy, or in some cases difficult. Getting a whole shaft assembly is definitely the easiest way to go.