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How-to

1992 Ford Bronco Front Axle U-Joint Replacement

1992 Ford Bronco · Repair · Expert

Documented by SuperMotors from Jeremy Millrood’s photos

The front axle shafts on a 1992 Ford Bronco were separated and their U-joints pressed out, with one joint needing a sledge hammer to free it from the inner shaft. New Brute Force U-joints were then seated and the caps pressed back on with a ball joint press.

  1. Step 1

    Clean the dirt off the yoke until the c-clips are visible, then drive the clips out. Jeremy Millrood removed one clip with a pick and had to use a punch on the others.

    Taking the c-clips out was a little difficult, I was able to get this one out with a pick, but the other ones I had to use a punch. There w… (1992 Ford Bronco)

  2. Step 2

    Press the bearing caps out with a ball joint press. Jeremy Millrood notes these were in tight and took some effort.

    Using the balljoint press to push the caps out, these were in pretty tight so it took a little effort. Make sure after you push the one sid… (1992 Ford Bronco) This is what it will look like once the cap has been pushed out. (1992 Ford Bronco)

  3. Step 3

    After the first cap is out and removed, press the opposite side of the U-joint out, which makes the joint easier to remove. The yoke at this stage shows the exposed cross and remaining cap packed with old grease.

    Make sure you push the opposite side of the u-joint out after you get one of the caps off. (1992 Ford Bronco) Close-up of a disassembled driveshaft universal joint (U-joint) yoke covered in old grease and grime, resting on a white cloth. One bearing… (1992 Ford Bronco)

  4. Step 4

    Lay the axle shafts out on the bench once the caps are off. Jeremy Millrood reports that one of the caps popped.

    Two splined axle shafts, one with a U-joint yoke still attached, laid out on a metal workbench alongside a wire wheel brush, an O-ring, and… (1992 Ford Bronco) Here are the caps after they had all been pushed off. One of the caps actually popped. (1992 Ford Bronco)

  5. Step 5

    With all of the caps pressed off, the U-joint may still not come free of the inner axle shaft. Jeremy Millrood tried every direction at this point without getting it out.

    All of the caps have been pushed off. Now I can't get the u-joint out of the inner axle shaft. I tried every direction and it would not com… (1992 Ford Bronco)

  6. Step 6

    Rest the base of the ears on a block of wood and strike the U-joint with a 5 pound sledge hammer. Jeremy Millrood reports it came out after 2 hits.

    Took a 5 pound sledge hammer, placed the base of the ears on a block of wood, and hit the u-joint. (1992 Ford Bronco) It came right out after 2 hits. (1992 Ford Bronco)

  7. Step 7

    Jeremy Millrood used Brute Force U-joints, part # 10297BF, for the front axles. Pull the end caps off the new joint carefully so the needles are not disturbed.

    These are the u-joints I used for the front axles, Brute Force, part # 10297BF. (1992 Ford Bronco) This is the u-joint, the end caps pull right off. Be careful with them, as you don't want to mess up the needles. (1992 Ford Bronco)

  8. Step 8

    With the caps removed, position the new U-joint between the two yoke ears, working it around as needed to get it to fit. The photos show the joint seated in the yoke from two angles before any cap goes on.

    After removing the caps, I positioned the u-joint betweent the two axle pieces. You may have to work it around a little to get it to fit. (1992 Ford Bronco) Here is another angle of the u-joint seated. The caps have not been installed yet. (1992 Ford Bronco)

  9. Step 9

    Start a cap onto the joint, then do the opposite side of the one started with, and press each cap home with the ball joint press. Jeremy Millrood says the caps slid on easily and recommends spending $100 on a decent press.

    Here I am about to push one of the caps on, they actually slid on pretty easily. Make sure you do the opposite side of the one you started… (1992 Ford Bronco) Pressing the cap on with a balljoint press, this is a great tool. I highly recommend spending the $100 bucks to pick up a decent one. (1992 Ford Bronco)

  10. Step 10

    Install the c-clips to finish the axle assembly. Jeremy Millrood seated them with a light tap from a hammer and a screwdriver. The last photo shows a c-clip in place on the joint while it is still in the press.

    Here is the axle completely assembled with the new u-joint installed. Now the tricky part is installing the c-clips, I put them on using a… (1992 Ford Bronco)

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