What is the best way to "peen" over the u-joint pin? I've tried putting a bolt in my vise and centering the drive shaft housing over it, then taking a punch and hammering it. It doesn't seem to want to go down far enough, because when I turn the end of the u-joint, I still hear a scraping sound every now and then. I think the pin is hanging up somewhere.
The driveshaft plug hole is a 1/2-20 thread. I make my own pin that fits the ujoint pin hole snug. My pin is made with a somewhat thin head on it that is larger OD than the pin but smaller than the threaded plug hole and with the other end drilled in its center with a small hole into the end of the pin. I put it in from one side and buy a hex bolt from Home Depot that has a 1/2-20 thread. I put the hex bolt into the plug hole against the head of the pin and snug that up to hold it fully inserted and then turn the driveshaft over and let the head of the bolt rest against my anvil to absorb the blow. I then drive a center punch into the drilled hole on the other side to begin spreading that pin. I finish up the job with a small flat ended punch to spread and flatten the pin end. I turn the thing back over and take out the 1/2-20 bolt and the job is done.
I pre peened one end before I inserted it in the ujoint. Hope that helps.
I do the same as John and James but I use a fan arm bolt (same thread) that I drilled a "pocket" in for the head of the pin that I pre-peened to settle in, tighten 'er up against the pin then flop (usually the rear axle assembly is involved as a unit) the assembly over on the concrete floor against a piece of wood and "get after it" !
There used to be aftermarket pins that had a low head on one side. They should make them again. I do mine like John says, and never have a problem.
Thanks for the helpful tips, guys! I got everything back together just fine.