Ok, here goes,
Identify which joint is in trouble, remove all circlips from bearing cups, they will be seized so a small whack with a hammer always works.
Place joint in vice as shown in pic, hit with hammer on prop joint, you should see the bearing cup rise from the yoke.
This is what you should see.
Flip the propshaft over & repeat the processs.
Part the 2 halves of the prop joint, you may have to remove sealing washers to achieve this. In this case, due to wear the washers had already fallen out
Take the other part of the propshaft & place in the vice, repeat the cup removal process as before.
The cups should rise as before.
Flip joint & remove other bearing cup.
Inspect for damage, as you can see on this flange it is beyond repair. So replace as necessary.
You may find a different design of circlip, these can be removed with pliers & a hammer.
Clean all yoke surfaces, I use a rotating rubber block with a tube of sandpaper around it which fits perfectly. Emery tape is as good.
Try & use a good quality propjoint as the cheap ones don't last. (We do carry a more than comprehensive stock!)
Remove all cups from spider joint do keep them clean
Place new spider into yoke,
Slide 1st cup joint onto spider, this keeps the needle bearings from falling out.
Place the other cup joint into the yoke & onto the spider, try & place spider half & half in each cup joint.
Press in 1st cup joint with an old socket until the 1st circlip groove is visible. Then fit the clip
Make sure circlip groove is clean & free of debris.
Press in 2nd cup bearing & fit circlip.
The joint should now look like this.
Take the other half of the prop shaft & slip the spider in to the yoke. Make sure grease nipples are lined up with each other as this makes it easier to grease when fitted to vehicle.
Slide cup bearings onto spider as before. Making sure the spider is half & half in each cup.
Press in 1st cup with old socket, until circlip groove can be seen. Fit circlip.
Flip prop shaft over & repeat the pressing in process on 2nd bearing cup. Fit circlip.
Your prop shaft will now be complete. You may find the joints are stiff to move. Place the prop shaft over the vice as before & tap each yoke so the bearing cup moves towards the circlip. This will free up the joint.
Refit grease nipples & grease joints as necessary. Refit to vehicle using new nyloc nuts.
Hope this is of use to anybody who has the same issues, hope this saves you a few pounds on repair bills
