As part of a front end rebuild on my 2006 Ram 2500 with the 5.7 engine, I replaced the u-joints. Of course it took far longer to remove them than youtube videos let on. that's fine.

However, the new spicer u joints are like a millimeter too wide - c-clip channel to c-clip channel. I got the clips into the slots on two sides, but had a terrible time getting the other sides in. I was using a ball joint press and was able to get excellent "press"ure on the joint - both ways. I can't believe that I compressed the yokes enough to bend them that one millimeter.

I did screw up one of the joints by pressing the end caps after some of the needle bearings left their vertical places. It was pretty amazing to see five or six of the bearings just shattered at the bottom of the cap when I took of the u joint to see what was going on. I got another one - user error - my punishment, a $60 replacement.

I'm wondering if anyone else has had a similar experience, and what happened if two of the four clips weren't 100% seated?

Jeff...