U-Joint strap slop - how much is too much - options for snugness?

[Jim]

I replaced the transfer case's front output seal today. Tightening the U-Joint straps onto the yoke I noticed one strap has about a business card thickness of gap between the bearing cap and the strap. There should be no slop / play there - yes? What options exist for a snug fit? Are different sized straps available?

[newracer]

Strap is stretched and worn out, get a new one.

ETA: you can get machined aluminum and steel replacements but you have to make sure they will clear.

[Spieg]

Definitely don't want any slop there. Do you have yokes that can be converted (drilled out) to use u-bolts?

[Jim]

It looks like U-Bolts could fit. I read about u-bolts since last night. I'm thinking my rear axle (D44) has U-Bolts in the rear yoke. Here's a pic of the back end of the front driveshaft / T-Case yoke:

I'll head to the parts store today and inquire about replacement straps and u-bolts.

Curious how an eye sees things differently in different scenarios. Last evening I had the yoke in my hands at the workbench. I cleaned much of the grime off of its surfaces. Only now, in the pictures, do my eyes focus on the hammer marks in the metal. I never needed to use a hammer to remove the yoke.

BONUS is the 3" body lift - almost all of the work is tended sitting alongside the jeep with arms between frame and body.

[Spieg]

It looks like that yoke could probably be drilled for u-bolts. It's important you have enough "meat" left around the enlarged holes to for sufficient strength as well as a flat surface for the nut/washer to seat on the back side of the yoke.

[Jim]

`picked up straps from NAPA this afternoon. I asked about bolts and they had some of those too - so I got a set of those as well. They might need to be returned for longer bolt length. I had measurements in advance but their best guess might need some tuning - we'll see. I'll look at nut face area before pulling a drillbit. As for this afternoon - straps to be replaced. Bolt conversion not before the run this weekend.

[4x4JeePmaNthINg]

Jim u bolt strap is much stronger, it looks like you've found an excuse to upgrade should you want to ha! I think I'll go that route some time down the road here.

Last summer we bought some napa straps for my friends wrangler, this was after his rear shaft grenaded on the highway. I remember the straps not sitting quite flush, I'll be curious if yours fit well?

[Jim]

I have new (Napa) straps on it now. The bolts I picked up are too short (exchanging tomorrow). The straps did not have the form I expected but when they snugged down the straps did "form fit" better to the bearing cup.

Best wishes on getting your electronics issue sorted.