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In Reply to: Front u-joint again! posted by Pat McCormick on Monday, April 14, 2008:
Mystery solved.
When my friend (30 years as a mechanic) installed the previous u-joint, one of the retaining rings didn't seat fully. After a while, the retaining poped off, and the bearing cap worked itself loose, and got lost. That's when the noise started up again.
This time, he made sure that all retaining rings were fully seated, and everything works great.