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U joint is 3 1/4 inches outside measurement. Compared with a new cap and it is the same so there is not a bearing lodged under the cap. Any ideas to get it through the knuckle.
I hope to know as well as this happens to me at times.
I recall having issues with recent U joints that may be related to your dilemma. I recall on two occasions the caps were positioned too far outboard and I was unable to install the snap rings. If I remember correctly I removed about .010" from both snap rings to make fit. I don't recall having this issue in the past.
FSJ Hybrid build thread: http://www.shopfloortalk.com/forums/...ad.php?t=43332
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