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Hi Guys,
not sure if anyone will have an answer for this, but here it goes.

Just got a 4wd ATV, the previous owner was slack on maintenance, and one of the cups of the uni joint had siezed and spun inside the driveshaft yoke, all others are fine. Looking for some advice on a repair to get it operational again with a new joint, it is the front shaft.

Space needing to be taken up is the thickness of a coke cad wrapped around 3/4 of the cap. Was thinking about cutting the ear of the yoke, in a variety of places, not all the way through, and welding it back up in the hope of shrinking a section enough that I can install the joint and maybe solder the rest in when installed.

Doesn't look easy to tack weld it in and run the risk of destroying the seal face on the joint with heat, they are really small.

Any advice from someone who has bodged this up before would be appreciated, thanks
 

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There's not really much you can do to repair that. You could braze it up and remachine it to size again but that needs to be done accurately.
The uj caps are thin walled and toughened which makes them brittle, so they need the support of the yoke to prevent them breaking the side out of the cup. I've seen people put caps back into out of round yokes and they don't last long.
Second have shaft perhaps and a new joint.. Or cut a yoke off something else and weld it on there..
 
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