U-Joint

This procedure covers removal and replacement of universal joints (U-joints) in the front and rear driveshafts of a 4WD 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Front driveshaft U-joint × 1 — Spicer 5-760X or equivalent
• Rear driveshaft U-joint × 1 — Spicer 5-1310X or equivalent
• U-joint strap bolts (if reusing straps) × 8 — Use OEM specification
• U-joint snap rings (if applicable) × 8 — Included with U-joint kit

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Raise vehicle with floor jack and support securely on jack stands under frame rails
4. Inspect driveshafts for worn or damaged U-joints (play, rust, or binding when rotated)
5. Spray penetrating oil on U-joint strap bolts and yoke nuts if rusty, allow to soak 15-20 minutes

Procedure

1. 1

   Mark driveshaft phasing and position
   Using paint marker or chalk, mark the orientation of all driveshaft yokes and slip yokes relative to each other. Mark the driveshaft flanges to the differential and transfer case flanges. This maintains proper driveline phasing and prevents vibration after reassembly. Take photos if needed for reference.
2. 2

   Remove rear driveshaft
   Remove the four U-joint strap bolts at the rear differential pinion yoke. On slip-yoke configurations, the transfer case end simply slides out of the transfer case tailshaft once the pinion end is disconnected; on flanged configurations, support the driveshaft and remove the bolts at the transfer case output flange. Carefully lower the rear driveshaft and remove from vehicle. Note that CV joint bolts may be used instead of U-joint straps on some configurations.
   ⚠Support driveshaft weight to prevent it from falling when final bolts are removed
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)

   CV Joint Bolts61 Nm (45 lb-ft)
3. 3

   Remove front driveshaft
   Remove the four U-joint strap bolts at the front differential pinion yoke. Remove the four bolts at the transfer case front output yoke or flange. Support and remove the front driveshaft from vehicle. Cap or cover the transfer case outputs to prevent contamination.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)

   CV Joint Bolts61 Nm (45 lb-ft)
4. 4

   Remove U-joint snap rings
   Clean the yoke ears and U-joint caps with wire brush. Using snap ring pliers, remove the internal or external snap rings (C-clips) from all four caps of the U-joint being replaced. Some U-joints use injected nylon retainers instead of snap rings - these must be drilled or ground out. Mark which type your driveshaft uses.
   ℹ️Snap rings may be internal (inside the yoke bore) or external (in grooves on outside of yoke)
5. 5

   Press out old U-joint caps
   Using a U-joint press or C-clamp with appropriately sized sockets, press one bearing cap partially out of the yoke ear. Use a socket slightly smaller than the cap diameter to push on the cap, and a larger socket on the opposite side to receive the cap. Once cap is pushed out far enough, grip it with pliers and remove. Rotate driveshaft and press out the opposite cap. Remove the cross from the yoke and repeat for remaining two caps.
   ⚠Apply pressure slowly and evenly to avoid damaging yoke ears; if cap won't move, tap yoke lightly with hammer while applying pressure
6. 6

   Clean yoke bores
   Thoroughly clean all four yoke bore holes using wire brush and solvent. Remove all rust, old grease, and debris. Inspect yoke ears for cracks, wear, or damage. If yoke ears are wallowed out or cracked, the driveshaft yoke must be replaced. Check that snap ring grooves are clean and undamaged.
7. 7

   Prepare new U-joint
   Remove new U-joint from packaging. Verify it matches the old joint size and style. Many U-joints come with grease zerk fittings - ensure the fitting is properly threaded into the cross. Remove one cap from the new U-joint and position the cross into the yoke with grease fitting aligned to access hole (if applicable).
8. 8

   Install new U-joint
   Start one bearing cap into the yoke bore by hand, ensuring needle bearings stay in place on the cross trunnion. Using the U-joint press or C-clamp, carefully press the cap into the yoke until it's flush with the snap ring groove. Install the snap ring in the groove. Rotate the assembly, install the opposite cap, and press it in until the first snap ring seats fully in its groove, then install the second snap ring. Repeat for the remaining two caps, ensuring all four snap rings are fully seated.
   ⚠Do not press caps too far or you will dislodge the opposite snap ring; press only until snap rings seat properly
   ℹ️U-joint cross should rotate smoothly in yoke after installation; if binding occurs, U-joint may be cocked or needle bearings displaced
9. 9

   Repeat U-joint replacement
   Repeat steps 4 through 8 for all remaining U-joints that require replacement on both front and rear driveshafts. Most driveshafts have two U-joints each (one at each end). Ensure proper phasing is maintained when installing U-joints - the yoke ears should be in the same plane at both ends of the driveshaft to prevent vibration.
10. 10

    Lubricate U-joints
    If U-joints are equipped with grease fittings (zerk fittings), use grease gun to pump fresh EP (extreme pressure) grease into each U-joint until clean grease appears at all four cap seals. Wipe away excess grease. This ensures proper lubrication and removes any air or contaminants.
11. 11

    Reinstall front driveshaft
    Position front driveshaft into vehicle, aligning marks made during disassembly. Install driveshaft to transfer case output yoke first, threading bolts by hand. Then align driveshaft to front differential pinion yoke and install U-joint strap bolts or CV joint bolts. Tighten all bolts to specification in a cross pattern.
    ℹ️Ensure alignment marks match to maintain proper driveline phasing
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)

    CV Joint Bolts61 Nm (45 lb-ft)
12. 12

    Reinstall rear driveshaft
    Position rear driveshaft into vehicle, aligning all marks made during disassembly. Install driveshaft to transfer case output yoke first, threading bolts by hand. Then align driveshaft to rear differential pinion yoke and install U-joint strap bolts or CV joint bolts. Tighten all bolts to specification in a cross pattern.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)

    CV Joint Bolts61 Nm (45 lb-ft)
13. 13

    Verify installation
    Rotate driveshafts by hand to ensure smooth rotation without binding or unusual resistance. Check that all snap rings are fully seated and all bolts are properly torqued. Verify no tools or parts were left under vehicle. Lower vehicle from jack stands.

Reassembly

1. Ensure all U-joint strap bolts and CV joint bolts are torqued to specification in a cross pattern to prevent distortion
2. Verify driveshaft phasing marks are properly aligned to prevent vibration
3. All greaseable U-joints should be lubricated until grease appears at all seals
4. Double-check that all snap rings are fully seated in their grooves

Verification

• Start engine and shift transfer case through all ranges to verify no binding or unusual noises
• Test drive vehicle at various speeds (15, 35, 55 mph) checking for vibration, clunking, or unusual driveline noises
• Perform figure-8 turns in both directions to load U-joints and verify smooth operation
• Re-check all driveshaft bolts for proper torque after test drive
• Inspect U-joints after 500 miles of driving for any signs of looseness or failure

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