[19Fordy]

Thanks to suggestions offered in my original post I was able to assemble the U-Joint using rebuild kit.

Sadly, I cracked one of the bearing bushings that fit into the yoke. I still finished the installation using that bushing. The bushing crack is almost imperceptible and is positioned at the bottom of the yoke opening as shown below.

Would it be ok to go ahead and use this U-joint as there is no direct load on the bushing/bearing? All is good except for the hairline crack.

Cost of rebuild kit plus shipping and tax was $82.39 so I would like to think I can still use the U-joint. I don't think I can buy a bushing separately. Thanks again, Jim

PS: To assemble, drop the cross bar (minus the bushings) into one of the yokes halves. Then gently tap on one bushing (with the inside chamfer facing inward (Photo 3) and tap it in just a little bit onto the crossbar and into the yoke. Don't tap it all the way in. Then flip the yoke over and you will find that you can pretty much center the opposite crossbar so it's visually "centered" in the yoke opening Photo 2. Then, insert the other bushing (inside chamfer facing inward) onto the opposite crossbar and gently tap it into the same yoke - a little bit equal to the opposite side. Then move the yoke back and forth to help center it. Then, alternately tap each bushing inward just a little bit onto the cross bar. Go from side to side and don't hit the bushing fully inward all at once. Keep moving the yoke to see if it swivels and keep tapping the bushing in to the correct distance where the grooves for the safety wire line up. This tapping action on each bushing is done while holding the U-joint in one hand and tapping the bushing inward. Follow this procedure for the other yoke and crossbar. I applied WD-40 to make surfaces slippery.

Unfortunately, I cracked a bushing while trying to obtain the best crossbar/yoke/bearing fit so it would swivel properly. If anyone has an extra bearing, bushing please keep me in mind.