Re: Rubicon axle u-joint failure
Thank guys -- after taking a real close look at it - it looks like on a full turn under acceleration, where the U-joint's taking lots of pressure, The joint moves slightly - the very thin clip, that's bareley longer than 180 degrees, gets loose and slips out. Then the bearing cap works it's way out. I caught mine before any damage occurred, even the end of the journal wasn't beat to death - looked like all it needed was a new bearing cap (no!)
The clip's just too damn short - doesn't go around the bearing cap enough.
I'm going to try putting a little tack weld glob on the yoke after the bearing's on - the outside - trying to keep most of the heat on the yoke. And - I'll try putting a small dab of JB Weld in the inside of the yoke - right where the clip would have to slide if it tried to come out, trapping it.
Next replacement time all it'll need is a grinder touched to the tacks on the outside to clean them off, and a chisel whacking the 2 or 3 drops of JB weld on the inside.
Seems like this problem is fairly common - I'd suggest everyone have a look at their axle joints every once in a while - may prevent problems on the trail or road.