RTH: What am I missing on mid-shaft U-joint replacement?!

Real time help please...

Evening all....I'm stumped and need the advice of the hive mind here.

I removed my rear DS today to replace the carrier bearing due to excessive play. This is on a 2014 SR5 DC w an OME lifts and a 1/2" carrier bearing drop. Truck has about 138K and is an AZ truck.

Removal of the UJ took some persuasion, but nothing worse than any other vehicle previously. Cutting the trunions always makes it go faster.

Here is where I am stumped though....I tried a 5-178x from Spicer, and a Napa UJ331 after I boogered the Spicer....I can get one set of trunions, caps and clips into the rear portion of the rear DS, but I cannot get the other set of trunions into the forward section. I can get one ear, but not both.

And then there is this conundrum....when testing out a previously boogered UJ, I pulled all the needle bearings out of the cap, and cleaned it of grease, and then I can get the UJ installed.

Is this an order of operations thing? What am I missing.

Thanks
Gavin

 

Apparently, 3rd time was indeed the charm.

I took a file to any burrs on the ears of the DS, and lightly greased the caps before installing. I also went and bought a ball joint press(big c-clamp style) and this made the install a breeze. Took her for a drive and no vibrations and no low speed growl like I had before.

So....if you haven't done so already, replace your carrier bearing.