Axle wont slide through knuckle!!??

[RougeRanger]

So I recently bought a 94 xlt and the 4x4 isn't working and a bearing is busted (probably because of locknut system) ? and I cant seem to get the u-joint through the knuckle! I'm here alone and thinking about putting something between the end of the radius arm and the center of the u-joint, then using power steering to basically press it out!?!? What's your thoughts? I am afraid it will tweak the radius arm before pushing out the axle but I'm alone and waiting for battery to charge.

 

[adsm08]

Have you removed the spindle from the knuckle? The axle shaft will never fit through the knuckle with the spindle still on, but should fit through relatively easily with it removed.

I think your PS idea is likely to break things.

 

[snoranger]

I think your PS idea is likely to break things.

You should try it!

Seriously, which side driver or passenger? The pass side has a boot at the slip joint that's clamped on. You have to remove the clamp to pull the outer half of the driveshaft. The drivers side should just come out.
Post pics, and someone will help you out.

 

[85_Ranger4x4]

Dana 28 / Dana 35 Repair & Rebuild - The Ranger Station

The Dana 28 axle assembly has been known to break under severe off-roading. Even the Dana 35 is prone to break under severe conditions, but is generally stronger than the Dana 28. If you plan on doing a lot of off-roading, … Continued

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The Spindle can be a pain to get out, especially if it hasn't been out before. Take your time and it will come out though.

 

[Jim Oaks]

So I recently bought a 94 xlt and the 4x4 isn't working and a bearing is busted (probably because of locknut system) ? and I cant seem to get the u-joint through the knuckle! I'm here alone and thinking about putting something between the end of the radius arm and the center of the u-joint, then using power steering to basically press it out!?!? What's your thoughts? I am afraid it will tweak the radius arm before pushing out the axle but I'm alone and waiting for battery to charge.

I've seen this before when people have tack welded the bearing caps in place, or there's been a u-joint failure. Look at it closely. It's probably just barely fitting somewhere. A metal file may help.

 

[adsm08]

I've seen this before when people have tack welded the bearing caps in place, or there's been a u-joint failure. Look at it closely. It's probably just barely fitting somewhere. A metal file may help.

I've seen rust scale cause it to not fit as well.

I've seen far more people who don't realize the spindle actually comes off the knuckle.

 

[Jim Oaks]

Sometimes it just has to all be perfectly lined up just right.

Make sure the knuckle is straight ahead. I think I've actually had to drive one through from the back side before.

 

[RougeRanger]

What do you think about wedging something behind the center of the u-joint to the back of the radius arm and using my power steering to help push it out of the knuckle?

 

[snoranger]

What do you think about wedging something behind the center of the u-joint to the back of the radius arm and using my power steering to help push it out of the knuckle?

I wouldn't, unless I had no other option.

 

[Jim Oaks]

Take a pry bar, stick it between the knuckle and the end of the beam, get it behind the yoke of the axle (where the u-joint is), and pry it out through the knuckle.

The axle went in though there, it will came back out through there.

It would be helpful if you posted some photos so we could see what you're working with.

 

[RougeRanger]

I tried adding pics and it said file is too large. How do u guys add pics? I'm not very tech savy

 

[RougeRanger]

Fyi this is on the right or passengers side. The problem isn't in the rubber boot I dont think! I can see where this u-joint has been replaced and is slightly bigger than factory. Also it looks like someone took a sledge hammer and beat it in there!

 

[RougeRanger]

So I called the previous owner and he said that he broke a hub and dug into the truck to find shredded bearings, replaced bearings and hub then 6 months later the bearings were shot and so he replaced the stub shaft and u joint and spindle and sold it! He said that when he tried to get the new u joint back in he had to beat it in with a bfh yet it came out from the boot back through the knuckle when he pulled it.

My problem now! I guess I'll give er hell one more again ?