Cant get u-joint cups to go in!!
 

I got new quicksilver u-joints PN 805536A2 for this Alpha Gen II outdrive I am working on. The serial number of the drive is 1FL60835. The u-joint cups WILL not press into the yoke at all. I tried deburing the edge of the yoke and putting a little grease on the surface. The old cups fit very nicely, but the new ones will not press in at all. I checked both boxes and the part numbers on the bags and the actual joints themselves and both new u-joints are exactly the same. Could I have the wrong u-joints?

Try and mic. them and see if they are the same size. They have always gone in fairly easy on the ones I have done.

Were the boxes sealed when you bought them? If not, possible the parts guy had two different joints out for a previous customer, and put the joints back into the wrong box...

Like Audiofn said, mic the caps and the yokes to double check.

Here is something I have noticed. The original u-joints were held in with a snap ring in a groove on the outside portion of the yoke and center socket. The new u-joint uses circlips on the caps on the inside of the yoke and center socket.

I miked the caps and they are 2 different sizes. Crap!! Back to the parts store tommorow

You have the wrong U-Joint crosses

You need part # 865494A01.