Alternate solution for u-joint removal

So the front u-joint on the rear shaft of my 1999 Z71 4x4 finally needed to be replaced. Short version - after trying the DIY method of pressing it out with a C Clamp and sockets and only succeeding in bending two old 8" clamps and a shiny new 10" Irvin while only popping 2 of the 4 caps I got a little frustrated.

Ended up taking a grinder to the cross itself and cutting it out leaving the caps themselves. Instead of simply taking a BFH and an old bolt to the caps to punch them out of an aluminum shaft I broke out the Dremel. The standard cut off wheels - as opposed to the fiberglass reinforced - were just the right size to fit in the cap opening of the shafts. With a few minutes careful cutting time an "X" was cut into each cap. After that the bolt and hammer did come out but it only took a couple of light taps to pop the caps out as opposed to full body blows. I believe that cutting the "X" in the caps allowed them to flex enough to loosen when tapped with the bolt/punch.

I've only done about a dozen u-joints in my lifetime and this just seemed like the least amount of physical exertion that was ever needed to replace one. Now pressing the new one IN was an entirely different story. Helps when they give you the right part to begin with. Fortunately, I caught it in time to swap it out.

So I guess I've got a question hidden here if anyone has a thought - what would the ramifications of installing a u-joint for a steel shaft in an aluminum shaft be?

the use of a small torch/heat usually allows removal with no damage...

I would only use the correct parts,,,or you may need a new drive shaft in time..

This one apparently just wanted to fight me j c. I did heat things up for a bit and even then it still managed to tweak a clamp on me.

The reason for the steel/alum u-joint Q is b/c the 1999s - at least my 99 - falls into that odd, late year release that very few parts places tend to think about. Y2K allows for an alum/steel shaft in many of the jobbers software programs but unless you're dealing with a human that actually knows this info, 99/late year release owners run the risk of getting a wrong part in general if they aren't aware of the issue. Even when I realized that I didn't have access to my grease gun and swapped the u-joint for a Brute Force joint the issue wasn't caught.

I actually called 9 different parts shops - all of them "major retail suppliers" - to double check this particular problem and only 2 of them caught the issue. And this was strictly b/c the parts human had come across the issue previously.

This one apparently just wanted to fight me j c. I did heat things up for a bit and even then it still managed to tweak a clamp on me.

The reason for the steel/alum u-joint Q is b/c the 1999s - at least my 99 - falls into that odd, late year release that very few parts places tend to think about. Y2K allows for an alum/steel shaft in many of the jobbers software programs but unless you're dealing with a human that actually knows this info, 99/late year release owners run the risk of getting a wrong part in general if they aren't aware of the issue. Even when I realized that I didn't have access to my grease gun and swapped the u-joint for a Brute Force joint the issue wasn't caught.

I actually called 9 different parts shops - all of them "major retail suppliers" - to double check this particular problem and only 2 of them caught the issue. And this was strictly b/c the parts human had come across the issue previously.

sometimes they can be a problem,,,more heat and a lot of cursing helps..thanks for that part difference info...

That's mainly why I figured I'd throw this up. I ran out of cursing and the heat didn't seem to be helping... ;) Once the grinder and Dremel came out effort was minimal and the only cursing involved was when sparks hit bare shins...:shakehead . Once the cross was out of the way and the caps were cut it was literally 3 or 4 easy taps and they fell right out.

first i call napa, ask and see if there machine shop guy is in. then i talk to him to see if the jobs are light that day and he can get me in. i pull the drive shaft. then i have a budy take me and the shaft down to napa. when i am there i tell the guy all the info on the truck he pulls the parts and gives them to the machine shop guy. in a few hours i get a call go pick up the parts and my buddy gets a nice lunch. i reinstall the drive shaft.

no fuss no muss. i even get the first grease job done there at the shop. :) you got to love a parts shop with a machine shop built right in.

now getting the guys behind the counter that know there parts thats somthing else. we had a parts shop here a older guy came in with a bad altnator. the new one was 200 bucks. the parts guy told the old man to hang on. he went in to the back pulled a second altnator. looked at what the differnce was. the second alt was 80 bucks and was missing a mounting hole. it had the space to drill the hole. the specks, and all the hookups were the same.

the parts guy told the old man we can not sell you a 200 dollar part. let me drill that hole and charge you a buck for the hole. the old man was happy. the parts guy sent all the 200 dollar alts back and stocked up on the cheaper ones with a note in his look up books to order that alt and drill that dango hole. and to tell the custmers about saving them a few bucks.

i wish that parts store was still going. but the chain parts stores killed it. it was a mom and pop type of shop. they had some good deals all you had to do was ask nicely. they would work with you just to keep you as a costmer.

Ahhh yes, the good ol' days of going to the local "mom and pop" autoparts stores and sitting at the counter waiting for the long-haired 20-something to come to the counter from the back. Meanwhile, Foreigner, AC/DC, or "insert band" are playing on some rock station on the radio while someone is jacking with a gold '75 Camaro out the parking lot with Cragars and slicks on the back.

Brings back many memories of going with my father to pick up some part for what he called a weekend "wrench party". I sure do miss those days and that man too!