U-joint snap ring flew off and U-joint cap blew up.

Hello and thank you for your help and guidance.

To keep it short. I had replaced the carrier bearing just like I've done before. No issues there. With that I also replace all three U-joints on the drive shaft just like I've done before. Everything was fine but the next day while driving over a bumpy driveway and accelerating up to 20 mph after getting to a paved road. It felt like something smaked the driver side wheel well very hard. Come to find out, one of the snap rings came off the u-joint close to the carrier bearing. The u-joint cap did not come off but it was not all the way in.

Thankfully I had an extra snap ring and used that to replace it. I had to press the u-joint cap back in. This for some reason made the other side get pushed out and warped the snap ring outwards a little bit. Didn't think much of it and after I replaced the missing snap ring I went ahead and pressed the other side in until the snap ring unwarped and went back to being flat against the u-joint cap.

Took the truck out for a test drive going over 60 mph 2 to 3 times. Went and check the u joint again and the snap ring held but the u-joint cap itself blew up. Please see images below. But not only that, a bit of metal broke off of the yoke. Part of the ring that makes the snap ring pocket, again please see images. Needless to say I will replace the u-joint but I'm not sure if I'm screwed when it comes to the yoke or if it's fine. What do you think or know. Also the u-joint and other caps were like new still (shame).

 

What brand ujoint? I remember I once bought a ujoint from autozone and the snap rings would not fit on two of the caps. I had no choice but to grind down the caps - just a tiny bit, like quarter of a millimeter was all it took. Yeah, you might need a new yoke. Who knows if it has stress marks.

 

You smashed a needle bearing into the top of the cap when installing the cap and the snap was never installed properly because of this. It's why it failed and the snap ring came off.

The yoke will be fine.

 

It's a Moog part.

Edit: My only concern with the yoke is balance. But I guess we'll see after I replace the u-joint and test drive it. Not sure how much can a tiny bit send it off balance. And for stress marks, I didn't see anything obvious and I had a very close look at it.

 

You're probably right. I'm usually very meticulous about everything I do especially when it comes to my baby. I didn't see or feel anything out of order but I'm not a mechanic.

 

Copy that, good luck sir.

Spicer is the way to go. They are not cost prohibitive and they make the center/carrier bearing and ujoints for Toyota. The one time I got the autozone ujoint is because my center bearing went to shits and I needed to replace the one ujoints to access the CB.

 

This. It is obvious when you look at the bearing cap it is bulged out and cracked.

 

I've done it myself and I'm pretty careful and would have bet a paycheck a needle hadn't slipped out of place.

 

Update:

I replaced it with a Spicer part. Went in like a charm. So much so that I dropped the c-clamp press on my face and busted my lip open. I drove it a couple times going over 60 mph. Checked the u-joint and everything seems to be holding so far. No balance or vibration issues even after going over 80 mph.

I think next time I will have to spend the money on a brand new drive shaft. Maybe the u-joint caps were off on tolerances but I had to fiddle with the caps a bit because I barely had enough space to place the snap rings in. Only on one yoke. I'm no expert but maybe the yoke in question is off. If anyone know the exact diameter of the rear yoke, that is the one close to the carrier bearing, let me know so I can check if it's shot. What do you think? I enjoy the knowledge and opinions of other taco enthusiasts.

 

Pushing one of the needle bearings over in the cap is common on install and you need to watch for it.
I found if you push the first cap in about half-way thru the yoke then you can then ensure the u-joint is in both caps as you push the 2nd one on then center both and add clips.
They often supply more than one thickness set of clips with the higher end u-joints from Spicer.
Got tired of having one of the rollers drop down even after adding more grease before install to "hold" them in.
I rent the big C-clamp free install tool at Advance or Autozone and don't beat in with a hammer anymore.

 

Not to argue but rather to have a discussion. I feel like I would not had been able to place the caps or a cap in all the way if there was a needle out of place or I was smashing a needle under the cap. I should mention, I was able to press the u-joint caps in with the c-clamp using just my hand (most of the way) and a small wrench. Did not require any effort at all. Maybe that's part of the problem but again, I'm no mechanic. All the other u-joint caps and snap ring fit in like charm, its the one yoke with the tolerance issue I think. Not my image but this is the yoke in question just to give you a better idea.

 

The needles are very fine it doesn’t take much to bend one at all.