Q: How to repair different types of universal joints, including outer snap-ring, injected plastic, and double cardan type constant velocity joints on Ford Bronco?
A: To service the outer snap-ring type universal joint, first, remove the driveshaft and mark the joint yokes' positions. Extract the snap-rings from the bearing cups, then use sockets or pipe pieces in a vise to press one cup while displacing the opposite one into a larger socket, gripping and twisting the bearing cup out with pliers. Clean the yoke and inspect for damage, then obtain a repair kit that includes trunnion, cups, needle rollers, seals, washers, and snap-rings. Before reassembly, pack grease into the trunnion reservoirs and needle bearings without displacing them. Position the trunnion in the yoke, partially install one cup, insert the trunnion, partially install the opposite cup, center the trunnion, and press both cups into place using sockets slightly smaller than the bearing cups, ensuring needle bearings remain in place. Install the snap-rings and align the shaft yokes to install the other bearing cups similarly. For the injected plastic type, destroy the production line plastic retainers and fit conventional snap-ring repair kits. Support the joint yoke in a press and use a forked tool to apply pressure to eject the bearing cups, then twist them out with a vise. Clean any plastic remnants and obtain a repair kit with a prelubricated trunnion assembly and other components. Assemble the joint, noting that snap-rings are installed inside the yokes, and if the joint is stiff after reassembly, apply hammer blows to free the bearing cups. For the double cardan type constant velocity joint, use an inspection kit to dismantle the joint for inspection, marking the flange and coupling yokes for reassembly. Disengage the flange yoke and trunnion from the centering ball, remove the seal, washers, spring, and ball seats, then clean and inspect all components for wear, replacing any damaged parts. Remove plastic from the coupling yoke groove if necessary, inspect and replace the centering ball if damaged, and press a new ball onto the stud. Lubricate all parts with grease from the repair kit and insert them into the ball seat cavity in the correct order, lubricate the seal lips, and press it into the cavity, filling it with grease. Finally, install the flange yoke to the centering ball, ensuring alignment marks are correct, and install the trunnion caps as previously described.