Lincoln Aviator: Driveshaft / Disassembly and Assembly - Driveshaft Universal Joint

Special Tool(s) / General Equipment

205-086 (T74P-4635-C) Installer/Remover, C-Frame and Screw

Materials

DISASSEMBLY

NOTICE: Do not, under any circumstance, clamp the driveshaft assembly in the jaws of a vise or similar holding fixture. Denting or localized fracturing may result, causing driveshaft failure during vehicle operation.

NOTE: This procedure is intended to be used for all U-joints with snap ring retainers.

1. Remove the front driveshaft.
   Refer to: Front Driveshaft (205-01 Driveshaft, Removal and Installation).
   

1. NOTE: Spline stud yoke shaft U-joint shown, others similar.

   Remove and discard the snap rings.
   

1. NOTE: Spline stud yoke shaft U-joint shown, others similar.

   Using the special tool, press the U-joint bearing cups out of the spline stud yoke shaft and remove the spline stud yoke shaft.
   Use Special Service Tool: 205-086 (T74P-4635-C)  Installer/Remover, C-Frame and Screw.

1. Using the special tool, press the U-joint bearing cups out of the driveshaft yoke. Remove and discard the U-joint.
   Use Special Service Tool: 205-086 (T74P-4635-C)  Installer/Remover, C-Frame and Screw.

1. NOTE: Inspect the bearing cup bores and retaining ring grooves. Remove any rust or other surface irregularities.

   NOTE: Spline stud yoke shaft U-joint shown, others similar.

   Clean and inspect the U-joint bearing cup surfaces.
   

ASSEMBLY

NOTE: Install the U-joint kits as complete assemblies only. Do not mix components from other U-joint kits.

1. Lubricate the U-joint bearing cup bores.
   Material: Motorcraft® Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B)

1. NOTE: The bearing cup needle bearings need to be in the correct position.

   Using the special tool, install the new U-joint spider and bearing cups into the driveshaft yoke.
   Use Special Service Tool: 205-086 (T74P-4635-C)  Installer/Remover, C-Frame and Screw.

1. Install the new bearing cup snap rings into the driveshaft yoke grooves.
   

1. NOTE: Front driveshaft to spline stud yoke shaft U-joint shown, others similar.

   Using the special tool, install the new bearing cups on the opposite side of the spline stud yoke shaft.
   Use Special Service Tool: 205-086 (T74P-4635-C)  Installer/Remover, C-Frame and Screw.

1. Install the new bearing cup snap rings into the spline stud yoke shaft grooves.
   

1. Rotate the spline stud yoke shaft to make sure the U-joints are free to rotate easily, without binding, before installing the driveshaft.
   

1. Install the front driveshaft.
   Refer to: Front Driveshaft (205-01 Driveshaft, Removal and Installation).