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I’m going through the process of replacing all U-Joints I have had no trouble with the 1/2 shafts but the drive shaft gave me some trouble. I pushed the U-Joint in too far and damaged the slip yoke. Is this beyond repair or should I be fine?
I suggest a small "half-round" hand file to knock down the high spots. The above post is in the right direction, but even a small bit in a Dremel can remove too much material very quickly. Doing it by hand will be quick and controlled. Obviously it depends on how much experience/time you've put in altering metals...but you've just experienced how soft aluminum is creating the gouges! Knock down the high spots and press in your new U-joints and send it👍
Just correcting your 'terminology' a bit, that's an 'end yoke' on the fabricated driveshaft, not a 'slip yoke'. The damage appears that it can be massaged and saved. The damage at first glance appears to be from a chisel driving the u-joint end cap out? If there's no damage to the retaining ring groove and the majority of the end diameter you should be fine. If you've doubts carry it to a driveline shop and ask them.
Gently file those nicks down, then take an old u-joint cap and drive it thru from the outside to push them thru . Dab of grease on the surfaces will ease work and prevent galling/ further damage. Good luck 👍🏻
As others have mentioned, i would press an old universal joint cap through it from the outside to clean up the burr damage . The rest of the housing looks fine, the universal joints are centered by the retainers that clip in to the undamaged grooves.
Slip Yoke Damage
