Differential yoke won’t fit on shaft

[LarryM]

I ordered new differential yolksand transfer case yolks after replacing my seals and none of them will fit, I tried tapping one on and it won’t go on. I heard there is a tool that you could press them on with but I can’t find anything available and if I try to pound them on I’ll do some damage as I already tried that on the front differential. Any advice would be very helpful. This goes on a 1950 M 38 Jeep with the Dana 25 front differential.

[bmorgil]

The yoke is a press fit. Here is a tool https://www.ebay.com/i/273947157071?chn=ps&norover=1&mkevt=1&mkrid=711-117182-37290-0&mkcid=2&itemid=273947157071&targetid=883054601419&device=c&mktype=pla&googleloc=9015127&poi=&campaignid=9241643027&mkgroupid=96862021434&rlsatarget=pla-883054601419&abcId=1141156&merchantid=8010134&gclid=Cj0KCQjw9ZzzBRCKARIsANwXaeJzxA6eaJ4l5_WdUewG cckpoNZFBTTi9VMoc47Ri9vPEm9yB_IpovIaAj8fEALw_wcB

Usually, you can use the old nut to draw the yoke on. Do not use the new nut. Tap the yoke on far enough to get a washer and the old nut on with full thread contact. Oil the threads and draw it on. Tools are out there. I only use mine when the yoke is particularly tight. Usually the larger axle models. You can usually pull the smaller model yokes on with the old nut. Let me know if you cant tap it on far enough to start the nut. You need FULL threads engaged on the nut before you start to draw it on, NOT just a few threads or the nut will strip. The pinion threads are hardened.

[LarryM]

Thank you for the reply, I could not get the yoke on far enough to start the nut on it to press it in any further. The shaft was pretty tight, with no play in it and after I started tapping in the yoke, it got side movement and in and out movement. I hope I didn’t damage anything. I see the tool that you Recommend is called a bearing tool but it looks like it would work for install in new yoke, is that correct?

[bmorgil]

Larry, on page 204 of the Universal Service manual there is a picture and description on the following page. That is the yoke installer I sent the link on. The tool can be used to pull the pinion through the front bearing and seat it prior to installing the yoke, if desired. This helps when it comes time to pull the yoke on with the same tool. In addition, you can get a preliminary look at the pinion torque to rotate, before installing the yoke.

[LarryM]

Thank you so much, I am going to order this. Where can I order the universal service manual from?

[gmwillys]

The military service manuals are available on line as a reprint, or like bellow, is an example of the original. The universal manual covers the same information as the TM manual, but the military has more information on the specialty equipment.


https://www.abebooks.com/servlet/BookDetailsPL?bi=21913904111&cm_mmc=ggl-_-COM_Shopp_Rare-_-naa-_-naa&gclid=EAIaIQobChMInvvCpsSU6AIVENbACh2Tog3rEAQYAiAB EgKqX_D_BwE

https://www.kaiserwillys.com/category/literature/mechanics-manuals

[LarrBeard]

I strongly suggest that you get a Mechanic's Manual (or military TM) as well as a Parts Manual for your Jeep.

By the way guys, this would be my other brother Larry.

[bmorgil]

By the way guys, this would be my other brother Larry.

Haha! Another classic sit com.

We are all brothers here Larry's! And we have a few sisters too.

[bmorgil]

The military service manuals are available on line as a reprint, or like bellow, is an example of the original. The universal manual covers the same information as the TM manual, but the military has more information on the specialty equipment.


https://www.abebooks.com/servlet/BookDetailsPL?bi=21913904111&cm_mmc=ggl-_-COM_Shopp_Rare-_-naa-_-naa&gclid=EAIaIQobChMInvvCpsSU6AIVENbACh2Tog3rEAQYAiAB EgKqX_D_BwE

https://www.kaiserwillys.com/category/literature/mechanics-manuals

They are on line here. Go to our "Tech Library".

https://willysjeepforum.kaiserwillys.com/forumdisplay.php?23-Tech-Library

The Military manual links are here, and a few more manuals get posted from time to time. You have to purchase the Universal Service Manual. I don't think it is online.

[LarryM]

I ordered that installation tool and it worked perfectly for the front and rear differential. The thread count on the front and rear differential is 16 with a three-quarter inch diameter nut. My transfer case apparently is an older version as it has the three-quarter by 20 thread count and this tool will not fit on the transfer case shaft. Can anyone help me find The three-quarter by 20 thread count installation tool? I contacted the seller of the previous tool and I’m waiting on a reply from him. Any help would be appreciated, thanks, Larry

[bmorgil]

Larry, you should not need a tool to install the output's on the transfer case. The axle's pinion shaft to yoke fit is definitely tight (or should be). The yokes to shafts on the transfer case, should not be that tight. They do get stuck on there once their torqued, and may require a puller to get off. You should be able to get the yoke on sufficiently to start the nut on the transfer case to install them however.

I am not aware of any tool to install the yokes.