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Volvo RWD 200 Forum

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1990 240 DL U joint change help 200 1990

Follow guidance on marking things.

You remove the retaining clips - I soak 'em with some PB Blaster before I start work. Stout needle nose will allow you to decompress the clips, and it usually takes a small screw driver with the other hand to pry it out. Watch here --- they like to go "flying". Once the clips are removed, I use a small socket and my big bench vice to push on the cap on one side, and a larger socket on the opposite end to support the DS or flange/yoke and allow the opposite cap to be pushed INTO the larger socket. It can take a lot of force to move these along -- lots of lube and sometimes a bit of heat will loosen things up. I've never used a hammer or a press - always been able to do it with a vice. Once you get the opposite cap extended beyond the joint, you remove the cap -- I usually grab it with channel locks and remove it (this is sometimes easier said than done). Then take your little socket from the other side, and use the open end of the socket to push on the joint the OPPOSITE way to push the other cap out the other side - use channel locks to remove the second cap. Then you can snake that part of the joint out of the shaft/or flange/yoke. Same process for the other two caps.

Clean everything up -- careful attention to clean/buff the bores that the new caps go in and the grooves that the new clips fit in. Pull the caps off the new joint - be sure needle bearings stay in place. Press cap into the bore; snake joint in between the two bores; use vice to press cap into bore and over the end of the joint. Then place cap into bore on the opposite end. Use vice/socket to move one cap past the retaining groove - insert clip. Then use vice/socket to push other cap on just barely far enough to get retaining clip in. DO NOT push new caps any further than needed to get clips in or you'll feel the joint bind. You should be able to move it with your hand even though it will loosen up a bit in use.

Hope that helps. Bound to be someone that has filmed this and put it on youtube. I just replaced 2 joints in mine day before yesterday. About an hour.






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New 1990 240 DL U joint change help [200][1990]
posted by  dkon77  on Tue Nov 1 18:05 CST 2016 >


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