7DEOH RI &RQWHQWV A3 DRIVELINES A3 Drivelines Troubleshooting ................................................11 Function............................................................15 Blue Bird Corporation assumes sole Servicing...........................................................16 responsibility for ensuring that the Shaft Support Bearing Assemblies .................16 information provided herein is accurate to Servicing the Driveshaft ................................16 the best of our knowledge at the time of Removal (Full Round End Yoke Style) ..........17 Removal (Half Round End Yoke Style)..........18 printing. In keeping with its policy of Removal (Flange Yoke Style) ........................18 continual product improvement, Blue Bird Disassembly..................................................19 reserves the right to change product Reassembly ...................................................20 information without notice and without Installation in Vehicle....................................22 incurring obligation. Some information Double-Cardan Constant Velocity Type Joint (Light Duty) ..................................................29 contained in this section has been re- Straightening and Balancing..............................34 published from the following publications: Straightening and Balancing The Driveshaft (All Types)...........................................................34 Dana Corporation Spicer® Universal Joint Angles and Phasing (All Types).....................35 Division, Spicer® Universal Joints and Field Problem Analysis (All Types) ...............41 Driveshafts Service Manual, 1000 through 1880 Series, Light, Medium and Heavy Safety Duty Vehicles, © Dana Corporation, Form Safety is always first foremost. #3264. WARNINGS and Cautions Diesel Progress Engines and Drives, A You must adhere to the WARNINGS and Primer on Torsional Vibration, by Carl Cautions to work safely. The WARNINGS Stahl, February 1991. and Cautions listed in this manual are Contents emphasized at point of use. Drivelines............................................................... 1 Contents............................................................. 1 Safety................................................................. 1 Warnings and Cautions ................................... 1 Inspection and Lubrication.................................. 3 These should be required prior to Inspecting and Lubricating the Driveshaft........ 3 performing the maintenance step following Lubrication Procedure for U-Joints.................. 5 the WARNING or Caution to prevent Specifications ..................................................... 7 personal injury or equipment damage. Light and Meduium Duty Applications............ 8 Double-Cardan Constant Velocity Type Joints. 8 Torsional Vibration Dampers.............................. 9 Torsional Vibration......................................... 9 050-1 A3 DRIVELINES WARNING DO NOT ENGAGE OR DISENGAGE DRIVEN SERIOUS PERSONAL INJURY, EQUIPMENT BY HAND FROM OR EXTENSIVE PROPERTY UNDER THE VEHICLE WHEN DAMAGE CAN RESULT IF THE THE ENGINE IS RUNNING. WARNING INSTRUCTIONS ARE NOT FOLLOWED. INSTALL A SUPPORT STRAP WHEN SERVICING A DRIVESHAFT TO PREVENT Caution PERSONAL INJURY. A SERIOUS OR FATAL INJURY Minor personal injury can result or CAN OCCUR: a part, an assembly, or the engine can be damaged if the caution IF YOU LACK PROPER instructions are not followed. TRAINING IF YOU FAIL TO FOLLOW WARNING PROPER PROCEDURES IF YOU DO NOT USE PROPER TOOLS AND SAFETY EQUIPMENT IF YOU ASSEMBLE DRIVELINE COMPONENTS IMPROPERLY IF YOU USE INCOMPATIBLE DRIVELINE COMPONENTS IF YOU USE WORN-OUT OR DAMAGED DRIVELINE ROTATING SHAFTS CAN BE COMPONENTS DANGEROUS. YOU CAN SNAG CLOTHES, SKIN, HAIR, HANDS, IF YOU USE DRIVELINE ETC. THIS CAN CAUSE COMPONENTS IN A NON- SERIOUS INJURY OR DEATH. APPROVED APPLICATION DO NOT GO UNDER THE VEHICLE WHEN THE ENGINE IS RUNNING. DO NOT WORK ON A SHAFT (WITH OR WITHOUT A GUARD) WHEN THE ENGINE IS RUNNING. 050-2 A3 DRIVELINES replacement is required, check for Inspection and Lubrication manufacturers recommendation regarding Inspecting and Lubricating the Driveshaft replacement frequency of the end yoke retaining nut. WARNING ROTATING SHAFTS CAN BE DANGEROUS. YOU CAN SNAG CLOTHES, SKIN, HAIR, HANDS, ETC. THIS CAN CAUSE SERIOUS INJURY OR DEATH. DO NOT WORK ON A SHAFT (WITH OR WITHOUT A GUARD) WHEN THE ENGINE IS RUNNING. Inspection To keep a vehicle operating smoothly and economically the driveshaft must be carefully inspected at regular intervals. Vibrations and U- joint and shaft support (center) bearing Figure 2: problems are caused by such things as loose end If the end yokes are tight, check for excessive yokes, excessive radial (side to side or up and radial looseness of the transmission output shaft down) looseness, slip spline radial looseness, and axle input and output shafts in their bent shaft tubing, or missing plugs in the slip respective bearings Figure 2. Consult Blue Bird yoke. for acceptable radial looseness limits and method of checking. Figure 1: Check the output and input end yokes on both the transmission and axle, or axles, for looseness. If loose, disconnect the driveshaft and retorque the end yoke retaining nut Figure 1, to specification found in Table 1. If yoke Figure 3: 050-3 A3 DRIVELINES Check for excessive looseness across the ends of the bearing assemblies and trunnions. This looseness should not exceed .006 inches maximum Figure 3. Figure 6: If run out readings are required, they should be taken with the driveshaft mounted in the vehicle Figure 6, with the transmission in neutral and Figure 4: the axle shafts pulled, or by jacking rear wheels off the ground and placing axles on jack stands. Check the slip spline for excessive radial This will allow rotating the driveshaft by hand movement. Radial looseness between the slip to check indicator readings. The run out yoke and the tube shaft should not exceed 0.007 readings taken at the various locations should inches Figure 4. not exceed an additional 0.010 T.I.R. over the manufacturers specified run out. Figure 7: Figure 5: For an inboard and outboard slip yoke assembly design, check to be sure the plug is not loose or Check the shaft for damaged, bent tubing or missing Figure 7. If it is repair or replace it. missing balance weights Figure 5. Make certain Loose or missing plugs are commonly caused there is no build up of foreign material on the by not enough driveshaft slip movement. shaft, such as undercoat or concrete. If found, it should be removed. 050-4 A3 DRIVELINES Lubrication ROTATING SHAFTS CAN BE Among the most common causes of joint and DANGEROUS. YOU CAN SNAG slip problems is lack of proper lubrication. CLOTHES, SKIN, HAIR, HANDS, Properly sized Spicer U-joints that are ETC. THIS CAN CAUSE SERIOUS adequately relubricated at recommended INJURY OR DEATH. intervals will normally meet or exceed vehicle operation requirements. Relubrication flushes DO NOT WORK ON A SHAFT the joints thus removing abrasive contaminants (WITH OR WITHOUT A GUARD) from the bearings. WHEN THE ENGINE IS RUNNING. Lubricants for Universal Joints DO NOT GO UNDER THE VEHICLE For a normal application, use a good quality WHEN THE ENGINE IS RUNNING. lithium soap base extreme pressure (E.P.) grease meeting the *N.L.G.I. grades 1 or 2 specifications. Grades 3 and 4 are not recommended because of their greater thickness. For a severe application, use a good quality lithium soap base or equivalent E.P. grease having an operating temperature range of +325 to -10 degrees Fahrenheit. In addition, the grease should meet the N.L.G.I. grades 1 or 2 specifications. Consult your local lubricant source for greases that meet these specifications. Initial Lubrication And Relube Cycles Spicer replacement universal joint kits contain only enough grease to provide needle roller bearing protection during storage. It is therefore necessary to completely lubricate each replacement kit prior to assembly into the yokes. Figure 8: Each cross lube reservoir should be fully packed with a recommended grease and each bearing Use the proper lubricant to purge all four seals assembly should also be wiped with the same of each U-joint. This flushes abrasive grease; filling all the cavities between the needle contaminants from each bearing assembly and rollers and applying a liberal grease coating on assures all four are filled Figure 8. Pop the seals. the bottom of each bearing assembly. Too much Spicer seals are made to be popped. grease may cause hydraulic lock-up, making If any seals fail to purge, move the driveshaft installation difficult. After the kits are installed from side to side and then apply gun pressure. into the yokes and prior to placing into service, This allows greater clearance on the thrust end they should be relubed, through the lube fitting, of the bearing assembly that is not purging. On using the same grease. Relube every 10,000 two-zerk kits, try greasing from the opposite miles or 1 month. lube fitting. For light-duty kits, check for a fully seated snap ring or burrs on the snap ring or Lubrication Procedure for U-Joints snap ring groove. (Except Double-Cardan Type Joints) Because of the superior sealing capability of the Spicer Seal design on the 1610, 1710, 1760, WARNING 1810 and 1880 Series, there will occasionally be 050-5 A3 DRIVELINES one or more bearing assembly seals that will not use a good E.P. grease meeting N.L.G.I. Grade purge. 1 or 2 specifications. Relube splines every 10,000 miles or 1month. Figure 9: