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Do you use a press to disassemble uni-joints?
I knock out all the clips, then rest one yoke across an open vise and strike the high yoke with a copper hammer.
I can knock every cup out like this, I have never had this issue as you describe it.
You are clearly bending the yoke, if you can't reassemble the joint correctly.
Hope this helps.
I do use a press to disassemble. However, I usually cut the centers of them out with a cutting torch before I do this to make it easier to press out the cups. But I still have the bending problem. In fact, I don't see how anyone presses them out as a whole unit. I tried this a couple times and ended up with broken yokes. I'm really not understanding how you are using an open vise to do this.
Search on youtube for "How to change universal joints with a vice".
There are many videos on there.
You can use a press but only to the point of where the cross touches the inside of the yoke.
Push one cup out and remove it, then push the cross back to push the opposite cup out.