Staked UJ replacement.

This is a quick "how I did it" and not a "how to guide", take any of this information and use it at your own risk.

Bearings - 24mm bearing caps and 63.3mm accross, £3.80 each.
Bearings are from a BMW/Mercedes - Part number GU200.
Original bearings for the prop were 24mm x 62.5mm, odd size and expensive as the cheapest I found them for was £30 each.
The extra 1.3mm isnt going to make a difference because there is no circlips to worry about.

Step 1

* Press out UJ's and remove bearing caps.
* You could use a reaming tool to remove the metal that holds in the bearing caps.
* We didnt have that option to hand so welded a bar to the cap and tapped/twisted them out.



Step 2

Clean out any of the remaining metal that was holding in the bearing caps.



Step 3

* Insert the new UJ's and bearing caps.
* You wont have circlips so you need to centralize the UJ yourself.
* We pushed the bearing caps in so they just engaged with the spider without pinching tight.



Step 4

* Cut 4 notches into the prop around the bearing cap areas.
* Clean well once done.



Step 5

* Make sure the bearings are still centralized.
* Drop on a washer the right size so it sits on the bearing cap.



Step 6

* Weld 4 spots to hold the washer on.
* Go back to 5 and repeat another 7 times   



Step 7

* Admire the resulting farm yard mechanics.



Now for the important bit, does it work.
Yes, test drove the van today, vehicle is quieter than before, will drive on tickover (wouldnt before because of the seized UJ).
A small amount of vibration at approx 3000-3500 revs but not enough to pinpoint to the propshaft, could be backlash in diff etc etc.

Is it worth doing - yes if not in a hurry and you like playing mechanics.

Will update this post when the UJ's fail if they do  

Pretty good job that!

Well worth trying if yer shafts shafted, so to speak

My shaft is shafted, but its the circlip type, would I just be able to do this but reuse the circlip instead of welding?

Staked UK's are not designed to be a servicable part by the average home mechanic hence the guide.
UJ's with circlips are much easier to do and easy enough for most home mechanics.
A good vice, some patience and a little know how and you are done. Rather than rewrite whats already been covered by many I suggest a quick google search for how to replace UJ's and you will find a good guide I am sure.
One hint I would say is place the new bearings in the freezer the night before, this way they usually shrink enough to just drop into place   
Also the bearing sizes are different, I dont have the size for the UJ's with circlips.

Update - Prop passed the MOT last week........woohoo.

Didn't think the prop shaft was part of the MOT.

Yeah, i'm pretty sure if there is excessive play in the prop it's a fail.

Edit- Just checked, i don't think it is actually. I think it can go down as an advisory though.

I'm half sure its not a test item..... half sure!

CV boots are, and a visual inspection of front drive shafts.

But no prop shaft inspection criteria.

But they could advisory it at testers discretion, or if dangerous fail the vehicle if it looks like a major hazard.

Sorry HJ, i just edited my post above

Never had a prop fail an MOT but have had an advisory for play in a UJ before.

Never had a prop fail an MOT but have had an advisory for play in a UJ before.

I've taken some inspiration from this thread, and have tracked down a suitable UJ to repair my 'cut'n'shut' propshaft, going to fit it all together at the weekend, and hopefully get the pickup in roadworthy condition again!

Update - Repaired prop developed vibration, once removed front bearing had gone notchy, ho hum.
Cant be bothered to mess about with the staked prop again.
Picked up a circlipped prop for free (favours owed) but its been dented both ends, probably squashed in a vice when having UJ's done and it vibrates but 80% less then the repaired staked prop.
Picked up a prop yesterday, good condition, circlipped UJ's £40 bargian, approx 1 inch longer than mine and a different size spline sliding over the gearbox output shaft.......sheesh.
Luckily the Piaggio Porter is a second vehicle so going to locate another prop.

It was a nice idea though, and a fair bit of work went into it.

The accuracy required to stop the UJ's from excessively wearing is quite high, and then there's the balancing which will be upset with the washers and welds.

I have a couple of cir clipped prop shafts which have a buggered UJ. They are 1.3 van ones.

So if you want one to rebuild we could organise something.

At least just swapping UJ's is pretty straight forwards as long as you keep the shaft aligned as it came apart with some marks.

I just payed £65 for 2 new uj's, not sure if thats cheap or not