U-Joint

This procedure covers the removal and replacement of the driveshaft universal joints (U-joints) on a 2008 Dodge Viper with 8.4L V10 engine and rear-wheel drive.

Warnings

Tools required

Parts

• Driveshaft U-joint(s) × 2 — Use OEM specification or Spicer 5-760X equivalent
• Driveshaft differential flange bolts (if reuse not recommended) × 4 — Use OEM specification

Fluids

• rear_diff — 2.75 qt

Preparation

1. Park vehicle on level ground and apply parking brake firmly
2. Place wheel chocks behind front wheels
3. Raise rear of vehicle with floor jack and support securely on jack stands at manufacturer-recommended lift points
4. Raise front of vehicle slightly to prevent differential fluid from draining excessively when driveshaft is removed
5. Allow exhaust system to cool completely if vehicle was recently driven

Procedure

1. 1

   Mark driveshaft alignment
   Using paint marker or tape, mark the relationship between the driveshaft and the differential flange, and between the driveshaft and the transmission flange. Also mark the driveshaft yoke-to-tube orientation. These marks are critical for maintaining proper driveshaft phasing during reassembly. Note: Use OEM specification (verify correct Viper driveline U-joint part number against manufacturer documentation)
2. 2

   Remove rear driveshaft flange bolts
   Position drain pan under differential. Remove the 4 bolts securing the rear driveshaft flange to the differential pinion flange. Support the driveshaft weight as you remove the final bolt to prevent it from dropping.
3. 3

   Remove front driveshaft connection
   Move to the transmission end of the driveshaft. Remove the 4 bolts securing the front driveshaft flange to the transmission output flange. Have a helper support the center of the driveshaft or use a strap to prevent it from falling.
4. 4

   Remove driveshaft from vehicle
   Carefully lower the driveshaft and slide it rearward to clear the transmission flange, then remove it from under the vehicle. Place the driveshaft on a clean workbench with the U-joint to be replaced accessible. Inspect both U-joints for wear, roughness, or play to determine which need replacement.
5. 5

   Remove U-joint snap rings
   Using snap ring pliers, remove the internal snap rings (circlips) from all four caps of the U-joint being replaced. There are 4 snap rings total per U-joint. Note the orientation and type of snap rings for reassembly.
6. 6

   Press out U-joint caps
   Position the driveshaft yoke in a U-joint press or use a C-clamp with appropriately sized sockets (one small socket to receive the cap being pressed out, one large socket to press against the opposite cap). Press one cap partially out until you can grip it with pliers, then remove it completely. Rotate the driveshaft 180 degrees and press the opposite cap out. Remove the cross from the yoke, then press out the remaining two caps from the other side. Keep needle bearings with their respective caps if reusing caps for inspection purposes.
7. 7

   Clean yoke bores
   Thoroughly clean the yoke bores with a wire brush to remove any rust, debris, or old grease. Inspect the yoke ears for cracks, elongation, or wear. If the yoke is damaged, the driveshaft assembly may need replacement.
8. 8

   Install new U-joint cross
   Remove one cap from the new U-joint and position the cross into one side of the yoke. Ensure the grease fitting (if equipped) is oriented correctly for accessibility once installed. Start one cap into the yoke bore by hand, ensuring the needle bearings remain in place inside the cap.
9. 9

   Press in first pair of caps
   Using the U-joint press or C-clamp setup, carefully press the cap into the yoke bore while guiding the cross trunnion into the cap. Press until the cap is seated far enough to install the snap ring in its groove. Install the snap ring on the first cap. Flip the driveshaft over, install the opposite cap onto the cross trunnion, and press it in until the snap ring groove is exposed. Install the second snap ring.
10. 10

    Install second pair of caps
    Rotate the driveshaft to access the remaining two cap positions. Install the third cap onto the cross trunnion and press it in until the snap ring groove is visible. Install the snap ring. Install the fourth and final cap, press it in, and install the final snap ring. Verify all four snap rings are fully seated in their grooves.
11. 11

    Verify U-joint installation
    Check that the cross rotates freely in both planes without binding. There should be no lateral play in the joint. If binding occurs, the needle bearings may be misaligned; if excessive play exists, the snap rings may not be fully seated. Tap the yoke ears lightly with a deadblow hammer to help seat the snap rings if needed.
12. 12

    Repeat for second U-joint if necessary
    If the second U-joint requires replacement, repeat steps 5 through 11 for the opposite end of the driveshaft. Ensure all alignment marks remain visible for reassembly.
13. 13

    Reinstall driveshaft
    Slide the driveshaft assembly back under the vehicle. Align the front flange with the transmission output flange using the alignment marks made during disassembly. Start all 4 front bolts by hand to ensure proper alignment before tightening. Align the rear flange with the differential pinion flange using the alignment marks and start all 4 rear bolts by hand.
14. 14

    Torque driveshaft bolts
    Torque the front driveshaft flange bolts to specification in a cross pattern. Then torque the rear driveshaft flange bolts to specification in a cross pattern. Apply thread locker to bolts if specified by manufacturer.
15. 15

    Check and refill differential fluid
    Check the rear differential fluid level through the fill plug. If fluid was lost during the procedure, refill with 75W-90 synthetic gear oil to the bottom of the fill plug hole. Reinstall the fill plug and torque to specification.

Reassembly

1. Ensure all alignment marks are matched correctly during driveshaft installation to prevent vibration
2. Verify all snap rings are fully seated in their grooves before operating the vehicle
3. Double-check that all driveshaft flange bolts are torqued to specification

Verification

• Lower vehicle to the ground and start the engine
• With the parking brake applied, shift through gears to verify no abnormal noises from the driveline
• Test drive the vehicle at various speeds, listening for vibration or clicking noises that would indicate improper U-joint installation or driveshaft phasing
• Re-check driveshaft flange bolt torque after the first 50-100 miles of driving

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