Another propshaft problem

I got a prob with a Def 90 96 300tdi front prop,,,, the gearbox end UJ gave up,,, got a GKN replacement from Island4x4,,,, the problem is it don't fit,,, it appears to be the same size as the old one but I cant get the second circlip to seat in the groove on both yokes,,, The bearing caps press all the way thro the yokes ( all 4 of um ) all the clips seat in the groves without the UJ in theres no dirt or rust on the yokes and the grooves are clear,,,, but it wont fit together, I seem to be a full groove width to long on both yokes,,,,,,,,,,, Yes I seated the cups in a vice, ive tried the clips with the caps under pressure, even stoned the clips to be sure they are flat and to spec,,,,,,,,,,,, and it still wont have it,,, any ideas apart from some counter banging at Issie 4x4

Sounds like you got the wrong ones. There is two (I think) different sizes although there is only a few mm difference in them. I made this same mistake a few weeks ago. I think mine were 78mm and the ones I was trying to fit were 82mm. Either that or one of the needles from the bearings has fell over and stopping the cups going all the way on??

Just checked and there is a 75mm and an 82mm version.

Hello Adam.

I have 75mm crosses,,,, and 75s came out cant be a dropped needle as its doing the same on both yokes and ive had them all out and checked

Thats odd. Always use GKN and have never had a problem. Have you tried getting a socket the same size as the circlip and pushing it on with a vice??

usually is a needle under the cap fallen over whilst assembling

Just had it all apart again its NOT a fallen needle... Havent tried a socket but just about the machine up a close fitting bar and see if that helps but if im honest I cant see that working as the cap clip will be pressed hard together but ill give it a try

providing joints ok some times you need to tap the yoke apart a little to get both cirlips to fit

Hello James,
Not sure on that one mate, these are missing by the thickness off the clip,, they aren't reaching the groove anywhere around its circumference, cant even get the ends to catch, were are talking around a mm not a few thou and its both yokes the same

youve either got poor or wrong ujs ,yokes need spreading or you need to remove plastic grease disc in bottom of caps, presumably you know to push the first cap nearly through yoke to aid fitting second cap

SORTED,,, Made up a pair of rams that are a close fit then slowly squeezed the lot in the vice,,,, I think I must have been pressing them a little out of line, with the rams in I was pressing square and they HAVE GONE IN... Cheers Lads, im a happy chappie again