I'm on the last leg of completing my front prop rebuild. Everything has gone pretty smooth until pressing on the last trunion cap. I need a 1/16 of an inch or less to get my last snap ring on but it won't budge. I pushed the joint in the opposite direction and ran into the same problem. Any suggestions????????

 

More than likely one of the little roller bearings in the cap feel over and is between the trunion end and cap. Could be on the one you can't fit, or the opposite one.

 

There was a roller bearing broken in one of the caps on the opposite end of the cardon and it was throwing the whole thing off. I had to completely disassemble it and put it back together. I used my calipers and checked one of the roller bearings from the old u joint and they matched up so I replaced the broken one with that. Just greased everything up and put my shaft back in. Everything's working fine now. Thanks.

 

You didn't mention anything about the centering ball, did you replace it?

 

I did replace the centering ball. The whole double cardon with the centering ball was new to me but wasn't too hard to figure out. There didnt seem to be anything wrong with the old joints but I'm 200 miles short of 100,000 and after reading some of the other posts I figured that it wouldn't be a bad idea to just replace everything while I had some time on my hands. Next will be changing my gear oil and tranny fluid.

 

Don't reuse old needle bearings. They wear to match the u-joint and will likely cause premature failure of a new one.
Also, calipers aren't accurate enough to measure a needle bearing.