How-to
1990 Ford Bronco Dana 44 Front Axle U-Joint Removal
TTB Blows pressed the u-joints out of a Dana 44 front axleshaft (5-297X joints) with a ball joint press held in a vise, after pushing off the inner snap rings with a punch. The album also shows a larger receiver the owner built so the same press handles the bigger Dana 60 caps. The photos cover removal only, not fitting new joints.
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Step 1
Remove the inner snap ring from the u-joint on the D44 front axleshaft. TTB Blows notes the ring can be hard to see and pushes off with a punch, and that a screwdriver will not work for this.
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Step 2
Mount a ball joint press in the vise. TTB Blows prefers this setup and reports buying the press on sale at Harbor Freight for $30.
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Step 3
With the clips removed, begin pressing one cap out of the yoke. The far side of the press carries a hole that accepts the cap as it comes out.
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Step 4
Once the first cap is out, flip the axle around in the press and press the opposite cap out.
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Step 5
The disassembled joint: the cross, two caps with their needle bearings fallen out of place, and the two snap rings.
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Step 6
Expect stubborn joints to spit the ends of their caps as they are pressed. TTB Blows loads up the press and then gives the joint a good whack to release it.
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Step 7
The larger caps on a Dana 60 front axle do not fit the press's existing hole, so TTB Blows built a bigger receiver and used it to press the Dana 60 joints. The second photo shows that press on a Dana 60 front axle, driven with an air impact wrench.
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Step 8
The album's photos end here, with the joints pressed out; no reassembly steps were documented.
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