you wouldn't have seen the needles unless you looked inside of the cap before you put it back on. the needles are just held in there by grease. sometimes one may pull out just a bit when you remove a cap and when you go to replace the cap and the cross or end of that little shaft will push the needle sideways under the end of the cap (dropped needle) and then you force the cap on and there isn't really any room there for that needle and causes you problems or it doesn't sit all the way into the yoke and you tighten up the little ubolts that hold it together and that causes your problems.
as Grigg says you need a new ujoint. don't drop any needles either installing it in the shaft or unto the rear flange. and don't put the d/shaft tubing in the vise.
it happens to just about everyone and iyt is marked up to experience
have a good one as it is not serious
ron
remember which way the zerk fitting faces when you install the cross in the shaft

Last edited by padresag; 11/03/2009 8:04 PM.