Hear that? That rhythmic clicking or clunking noise coming from underneath your rig when you hit the gas. You feel that weird vibration through the floorboards that wasn’t there last weekend. If you’re a Can-Am Outlander owner who loves to push your machine, you’ll likely agree that these are the dreaded sounds of a failing U-joint.
Don’t let it sideline your next adventure. We promise this guide will give you the confidence and the know-how to tackle this job yourself. You’ll not only save a hefty bill from the shop but also gain a deeper understanding of your machine.
In this comprehensive guide, we’ll walk you through everything from diagnosing the problem and gathering the right tools to a detailed, step-by-step can am outlander u joint replacement. We’ll even cover pro tips and post-job care to keep you riding smoothly for seasons to come.
What Are U-Joints and Why Do They Fail on Your Outlander?
Before we get our hands dirty, let’s quickly cover the basics. A universal joint, or U-joint, is a simple but brilliant piece of engineering. It’s a cross-shaped joint with four bearing caps that allows your driveshaft to transmit power at an angle as your suspension travels up and down.
Your Can-Am Outlander has these critical joints on its front and rear driveshafts, connecting the transmission and differentials to the wheels. They are constantly under immense stress, especially when you’re crawling over rocks or blasting through mud.
Failure is often a matter of when, not if, due to the harsh environments these ATVs live in. Common culprits include:
- Water and Mud Intrusion: The number one enemy. Grime works its way past the seals, contaminating the grease and grinding away at the delicate needle bearings inside the caps.
- Lack of Grease: For serviceable (greasable) U-joints, neglecting a regular shot of grease from a grease gun is a death sentence.
- High-Impact and High-Torque Riding: Big lifts, oversized tires, and an aggressive riding style all put extra strain on your entire driveline, especially the U-joints.
- Simple Wear and Tear: Nothing lasts forever. Over time, the metal bearings and surfaces simply wear out from thousands of rotations under load.
Telltale Signs: How to Know Your U-Joints Are Shot
Your Outlander is pretty good at telling you when something is wrong. You just need to know how to listen. Ignoring these signs can lead to catastrophic failure, potentially damaging your driveshaft, yoke, or even your transmission case—a much more expensive repair.
Here are the classic symptoms of a failing U-joint that signal it’s time for a can am outlander u joint replacement.
The Sounds of Failure
Listen closely for distinct noises, especially when transitioning from a stop or changing from forward to reverse.
- A sharp “clink” or “clunk” when you shift into gear or get on and off the throttle. This is the sound of slack in the joint being taken up.
- A rotational squeaking or chirping noise that increases with your speed. It often sounds like a flock of angry birds living under your ATV.
The Feel of a Bad Joint
Vibrations are another major red flag. A worn U-joint can throw the driveshaft out of balance.
- A new vibration you can feel in the seat or floorboards. It may only appear at certain speeds and then smooth out.
- A rough or grinding feeling that seems to come from the center of the machine.
The Visual Inspection
The most definitive test is a physical check. Safely secure your ATV, then get underneath and grab the driveshaft near the U-joint.
- Try to twist the driveshaft back and forth. If you feel any play or hear a clunk before the yoke on the other side moves, the joint is bad. A healthy U-joint has zero rotational slop.
- Look for signs of rust dust (a reddish powder) around the bearing caps, which indicates the internal bearings have disintegrated.
Gearing Up: Tools and Parts for the Job
A successful repair starts with having the right equipment on hand. Fumbling for tools mid-job is frustrating and can lead to mistakes. This section of our can am outlander u joint replacement guide ensures you’re fully prepared.
Essential Tools You’ll Need
You don’t need a full professional shop, but some specific tools make this job infinitely easier and safer.
- Safety Gear: Always start with safety glasses and mechanic’s gloves.
- Jack and Jack Stands: To safely lift and support your ATV. Never work under a machine supported only by a jack.
- Socket and Wrench Set: You’ll need metric sizes for the driveshaft bolts. A breaker bar is helpful for stubborn bolts.
- Torque Wrench: Crucial for properly tightening the driveshaft bolts during reassembly.
- Snap Ring Pliers: Essential for removing the small clips that hold the U-joint in place.
- Bench Vise: A sturdy vise mounted to a workbench is your best friend for pressing the old joint out and the new one in.
- U-Joint Press Tool (or Sockets): A dedicated ball joint/U-joint press is ideal. However, you can get the job done with a large C-clamp and a socket that’s slightly smaller than the U-joint cap and another that’s slightly larger.
- Hammers: A dead blow hammer and a small ball-peen hammer are very useful.
- Pry Bar & Wire Brush: For persuading the driveshaft and cleaning the yoke bores.
Choosing the Right Replacement U-Joints
When it comes to parts, you have options. You can go with OEM (Original Equipment Manufacturer) parts from Can-Am or choose from a variety of quality aftermarket brands like All Balls Racing, Moose Racing, or EPI.
The main decision is between greasable and non-greasable (sealed) joints.
- Non-Greasable (Sealed): These are often what comes from the factory. They are fit-and-forget but have a finite lifespan. Once the factory grease is gone or contaminated, the joint is done.
- Greasable (Serviceable): These have a zerk fitting that allows you to pump fresh grease in, purging out old grease, water, and contaminants. They can last much longer if you stick to a regular maintenance schedule. For serious off-roaders, this is often the preferred choice.
The Main Event: Your Step-by-Step Can Am Outlander U Joint Replacement Guide
Alright, tools gathered and new parts on the bench? Let’s get to it. Take your time, follow these steps, and you’ll have this job done right. This is the core of how to can am outlander u joint replacement.
Safety First & Preparation
Park your Outlander on a flat, level surface. Chock the wheels that will remain on the ground. Safely lift the end of the ATV you’re working on and secure it firmly on jack stands.
Mark and Remove the Driveshaft
Before you unbolt anything, use a paint marker or punch to make alignment marks on the driveshaft yoke and the differential/transmission yoke. This ensures you reinstall it in the same orientation, maintaining its balance. Now, remove the bolts holding the driveshaft in place. You may need a pry bar to gently pop it free.
Remove the Old U-Joint Snap Rings
Take the driveshaft to your workbench. Using your snap ring pliers, carefully remove the four external or internal snap rings (circlips) that secure the U-joint caps in the yoke. This can be a bit tricky, so be patient.
Press Out the Old U-Joint
Secure the driveshaft yoke in your bench vise. Place a socket that is slightly smaller than the bearing cap on top of one cap. Place a socket that is slightly larger than the bearing cap on the bottom yoke opening. Tighten the vise to press the top cap down and into the larger socket below. Repeat for the opposite side. Once two caps are out, the cross can be removed.
Clean and Inspect the Yoke
This step is critical for a long-lasting repair. Use a wire brush and brake cleaner to thoroughly clean the yoke bores where the new caps will sit. Inspect the bores for any burrs, scoring, or damage that could prevent the new cap from seating properly.
Install the New U-Joint
Carefully remove two opposite caps from the new U-joint. Be extremely careful not to disturb the tiny needle bearings inside. Place the U-joint cross into the yoke. Now, gently press the new caps into place one at a time using your vise. Make sure the cross enters the cap squarely so you don’t dislodge any needle bearings. Press the caps in just far enough to install the new snap rings.
Install New Snap Rings and Grease
With the caps properly seated, install the new snap rings provided with your kit. Ensure they click securely into their grooves. If you’re using a greasable joint, now is the time to pump it full of quality marine-grade grease until you see fresh grease purging from all four seals.
Reinstall the Driveshaft
Take the rebuilt driveshaft back to your Outlander. Align the marks you made earlier and bolt it back into place. It’s a good practice to use a drop of blue Loctite on the bolt threads. Use your torque wrench to tighten the bolts to the manufacturer’s specified torque.
Best Practices and Pro Tips for a Flawless Job
Doing the job is one thing; doing it like a pro is another. Here are some can am outlander u joint replacement tips that can make the process smoother and the repair last longer.
- Freeze the New Joint: A classic mechanic’s trick. Place your new U-joint in the freezer for an hour before installation. The cold will cause the metal to contract ever so slightly, often allowing the caps to be pressed in with much less force.
- Patience with Needle Bearings: If a needle bearing falls out of place inside the cap during installation, the joint will fail prematurely. If you feel resistance, stop, back off, and check that all bearings are still standing up straight.
- Never Hammer Directly on the Yoke or Caps: Always use a socket or a block of wood as a buffer if you need to tap something into place. Direct hammer blows can distort the yoke or damage the new bearing caps.
- Check for Binding: After installing the new joint but before reinstalling the driveshaft, move the joint by hand through its full range of motion. It should be smooth and firm, with no tight spots or binding.
Beyond the Wrench: Sustainable U-Joint Care and Eco-Friendly Practices
Being a responsible rider extends beyond the trail. A key part of a sustainable can am outlander u joint replacement is focusing on longevity and proper disposal.
The best practice is preventative maintenance. If you install greasable U-joints, make greasing your driveline part of your pre-ride or post-wash routine. This simple act is part of a good can am outlander u joint replacement care guide, drastically extending the life of the part, reducing waste, and saving you from doing this job again anytime soon.
When it comes to being eco-friendly, don’t just toss the old parts in the trash. The old steel U-joint can be recycled at a local scrap metal facility. Collect any used, greasy shop towels and solvent in a sealed container and take them to your local hazardous waste disposal site for proper handling.
Frequently Asked Questions About Can Am Outlander U-Joint Replacement
How often should I replace my Can-Am Outlander U-joints?
There’s no set mileage or hour interval. Replacement is based entirely on condition. You should physically check them for play every time you change your oil or wash your machine. For aggressive riders who see a lot of mud and water, this check should be even more frequent.
Can I ride my Outlander with a bad U-joint?
We strongly advise against it. A slightly worn joint will get worse quickly. A complete failure can cause the driveshaft to break free while you’re moving, which can destroy surrounding components, lock up your wheels, and cause a serious accident. If you detect a bad U-joint, park it until it’s fixed.
Greasable vs. Non-Greasable U-Joints: Which is better?
It depends on you. Non-greasable joints are convenient and clean, but their lifespan is fixed. Greasable joints require regular maintenance but can last significantly longer if you take care of them, making them a popular choice for enthusiasts who don’t mind a little extra upkeep for added durability.
How much does it cost to have a shop replace a U-joint?
Labor rates vary, but you can generally expect a shop to charge 1-2 hours of labor per U-joint, plus the cost of the part. This can easily add up to a few hundred dollars. By doing it yourself, you only pay for the part—typically $30-$60—and gain invaluable experience.
Tackling your own can am outlander u joint replacement is one of the most rewarding DIY jobs an owner can perform. It’s a direct investment in the reliability and longevity of your machine.
You’ve learned how to spot the symptoms, what tools to use, and the exact steps to get it done. By taking your time and following this guide, you can restore that smooth, solid driveline feel and ride with the confidence that your Outlander is ready for whatever the trail throws at it.
Now get those tools out, put on some tunes, and give your Can-Am the attention it deserves. Happy wrenching, and we’ll see you on the trail!
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