U-Joint

This procedure covers the removal and replacement of universal joints (U-joints) in the front and/or rear driveshaft on a 2007 Ram 3500 with 5.9L Cummins diesel and 4WD.

Warnings

Tools required

Parts

• U-joint (front driveshaft) × 1 — Spicer 5-760X or equivalent
• U-joint (rear driveshaft) × 1 — Spicer 5-1310X or equivalent
• U-joint snap rings (if not included with U-joint) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Raise vehicle with floor jack and support securely on jack stands at frame rails
4. Identify which U-joint(s) require replacement by checking for play, binding, or rust damage
5. Determine if front or rear driveshaft service is needed (front driveshaft connects transfer case to front differential, rear connects transfer case to rear differential)

Procedure

1. 1

   Mark driveshaft orientation
   Before removing anything, use a marker or paint pen to mark the relationship between the driveshaft yoke and the pinion flange (or transfer case flange). Mark the shaft tubes and slip yoke if present. This ensures proper phasing during reinstallation which is critical for preventing vibration.
2. 2

   Remove driveshaft
   Remove the bolts securing the driveshaft to the differential pinion flange and transfer case flange. On rear driveshaft, the attachment may use U-bolt straps or a bolted companion flange - verify the fastener type and count on your specific vehicle before proceeding. Support the driveshaft while removing the final bolts. Slide the driveshaft off the slip yoke if equipped, being careful not to drop it. Lower the driveshaft and remove from vehicle. Place on clean work surface.
3. 3

   Clean and inspect driveshaft
   Use wire brush and brake cleaner to clean the yoke ears and bearing cap areas. Inspect the yoke ears for cracks, wear, or damage. Check that the bearing bores are round and not wallowed out. If yoke damage is present, the entire driveshaft or yoke assembly may need replacement.
4. 4

   Remove U-joint snap rings
   Locate the snap rings that retain the U-joint bearing caps in the yoke. These may be internal (inside the bore) or external (in a groove on the outside). Use appropriate snap ring pliers to remove all four snap rings from the U-joint being replaced. Keep snap rings organized as they may differ slightly in size.
5. 5

   Press out first bearing cap
   Position the driveshaft yoke in a U-joint press or use a C-clamp setup with appropriate sized sockets. Place a larger socket against one bearing cap to receive it, and a smaller socket on the opposite cap to push against. Slowly press the bearing cap out. If using C-clamp method, tighten gradually and evenly. The cap should press out smoothly once the snap ring is removed.
6. 6

   Remove U-joint cross
   Once the first bearing cap is pressed out far enough, remove it by hand or with pliers. Rotate the driveshaft 180 degrees and press the U-joint cross back through the yoke to expose the opposite bearing cap. Remove that cap. The U-joint cross can now be rotated 90 degrees and the remaining two caps can be pressed out from the other plane of the yoke. Remove the old U-joint completely.
7. 7

   Clean bearing bores
   Thoroughly clean all four bearing cap bores in the yoke using brake cleaner and a wire brush. Remove any rust, old grease, or debris. Inspect the snap ring grooves for damage. The bores must be clean for the new U-joint to install properly and for snap rings to seat correctly.
8. 8

   Prepare new U-joint
   Remove new U-joint from packaging. Most U-joints come with bearing caps loosely installed and held with tape or clips. Note that some U-joints have a grease fitting - orient this so it will be accessible when installed. Remove one bearing cap from the U-joint cross, being careful not to let needle bearings fall out.
9. 9

   Install U-joint cross in yoke
   Insert the U-joint cross into the yoke from one side, aligning one trunnion (arm) with the bearing bore. Start one bearing cap by hand into the bore, ensuring it goes in straight. The needle bearings should stay in place if you work carefully. Press or tap the bearing cap in just far enough to hold the cross in position.
10. 10

    Install opposite bearing cap
    Align the opposite trunnion with its bore and start the bearing cap by hand. Use the U-joint press or C-clamp to press both caps in evenly until the snap ring grooves are exposed on both sides. Be careful not to press too far or the snap rings won't install. Check that both caps are pressed in evenly.
11. 11

    Install snap rings on first axis
    Install new snap rings (or reuse old ones if in good condition) in the grooves on both bearing caps you just installed. Ensure snap rings are fully seated in their grooves. You should not be able to press the bearing caps any further inward - the snap rings should bottom against the yoke.
12. 12

    Install remaining bearing caps
    Rotate the driveshaft 90 degrees to access the other two bearing cap positions. Remove the temporary caps from the new U-joint. Install the remaining two bearing caps using the same process: start by hand, press in evenly until snap ring grooves are exposed, then install snap rings. Ensure all four snap rings are properly seated.
13. 13

    Check U-joint movement
    Verify the U-joint moves freely without binding. There should be no side-to-side play in the bearing caps. If equipped with a grease fitting, use a grease gun to pump fresh grease into the U-joint until you see fresh grease purge from all four bearing cap seals. Wipe away excess grease.
14. 14

    Reinstall driveshaft
    Position the driveshaft back in the vehicle, aligning the marks made during disassembly. If equipped with a slip yoke, slide it into the transmission or transfer case extension housing. Install the driveshaft bolts at both flanges, aligning the marks. Hand-tighten all bolts first, then torque in a cross pattern. Torque specs for this vehicle vary by attachment type: flange bolts and U-bolt strap nuts have different specifications. Consult the factory service manual for the exact torque values for your driveshaft's attachment style before final tightening.

Reassembly

1. Ensure all driveshaft alignment marks are properly matched to prevent balance issues
2. Verify all snap rings are fully seated and bearing caps cannot move axially
3. If multiple U-joints were replaced, ensure proper phasing between them (yokes should be in-plane)
4. Double-check that all driveshaft mounting bolts are torqued to specification

Verification

• Rotate the driveshaft by hand to verify smooth operation without binding or rough spots
• Check for any lateral play in the U-joints - there should be none
• Start the vehicle and listen for any unusual vibrations or noises
• Test drive the vehicle at various speeds, checking for vibration that could indicate improper driveshaft phasing or balance
• After test drive, re-inspect U-joint installation and verify all fasteners are tight

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