Spicer 2007 User Manual
Spicer
®
Driveshafts
Service Manual
DSSM3264
September 2007
Table of Contents
Safety . . . . . . . . . . . . . . . . . . . . . . 1
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Safety . . . . . . . . . . . . . . . . . . . . . . 2
Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
End Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Universal Joint . . . . . . . . . . . . . . . . . . . . . . 2
Slip Member . . . . . . . . . . . . . . . . . . . . . . . . 2
Yoke (Includes Slip Yoke, Yoke Shaft,
and Tube Yoke) . . . . . . . . . . . . . . . . . . . . . . 2
Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Midship Nut . . . . . . . . . . . . . . . . . . . . . . . . 3
Center Bearing . . . . . . . . . . . . . . . . . . . . . . 3
Foreign Material . . . . . . . . . . . . . . . . . . . . . 3
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubrication (When Applicable) . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . 5
End Fitting Inspection . . . . . . . . . . . . . . . . . . . . 5
Bearing Plate (Full Round) Yoke
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Quick Disconnect™ (Half Round) End
Yoke Inspection . . . . . . . . . . . . . . . . . . . . . 7
Universal Joint Inspection . . . . . . . . . . . . . . . . . 8
Re-lubable Style Universal Joints . . . . . . . . 8
Permanently Greased Plug Style
Universal Joints . . . . . . . . . . . . . . . . . . . . . 8
Slip Member Assembly . . . . . . . . . . . . . . . . . . . 9
Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Center Bearings . . . . . . . . . . . . . . . . . . . . . . . 10
Midship End Fitting . . . . . . . . . . . . . . . . . . 10
Lubrication . . . . . . . . . . . . . . . . . . .11
Spicer 10 Series™ Universal Joint and
Slip Members Lubrication Intervals . . . . . .11
Lubrication for Universal Joints . . . . . . . . . . . .12
Grease Compatibility . . . . . . . . . . . . . . . . .12
Lubrication Procedure for Universal Joints 12
Quick Disconnect™ (Half Round)
Universal Joints . . . . . . . . . . . . . . . . . . . . .13
Bearing Plate (Full Round) Universal
Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Snap Ring Universal Joints . . . . . . . . . . . .14
Lubrication for Slip Members . . . . . . . . . . . . .15
Lubrication of Center Bearing Assemblies . . . .15
Disassembly and Reassembly . . . . .16
Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . .16
Disassembly - Snap Ring Design . . . . . . . .16
Reassembly - Snap Ring Design . . . . . . . .17
Disassembly - Bearing Plate Style . . . . . . .18
Reassembly - Bearing Plate Style . . . . . . .18
Center Bearing Assembly . . . . . . . . . . . . . . . . .20
Disassembly - Inboard Slip Style . . . . . . . .20
Midship Nut Specifications Table . . . . . . . .22
Disassembly - Outboard Slip Style . . . . . . .23
Reassembly - Inboard Slip Style . . . . . . . .24
Recommended Center Bearing
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . .24
Midship Nut Installation Procedure . . . . . .24
Reassembly - Outboard Slip Style . . . . . . .25
Recommended Center Bearing
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . .25
Grease Zerk (Nipple) Fittings or Plugs . . . . . . .26
Universal Joints and Slip Member
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .26
Universal Joint Grease Zerk (Nipple)
Fitting and Plug Torque . . . . . . . . . . . . . . .26
Glossary . . . . . . . . . . . . . . . . . . . .27
Safety
Safety
Note: Spicer 10 Series™ Driveshafts are found on vehicles
throughout the world. Therefore, this manual includes
worldwide terminology.
General Safety
The following WARNINGS and CAUTIONS should be read and
understood before attempting any service or repair on the various components of the driveshaft assembly.
CAUTION
Under no circumstances should individuals attempt to perform driveline service and/or maintenance procedures for
which they have not been trained or do not have the proper
tools or equipment.
WARNING
Failure to take common sense, precautionary measures
when working on a vehicle or other machinery could result
in property damage, serious personal injury, or death. To
avoid property damage, serious personal injury, or death,
please follow basic safety rules as noted below.
1. ALWAYS wear safety glasses when performing
maintenance or service. Failure to do so can result in
personal injury and/or partial or complete vision
loss.
2. NEVER perform service or maintenance tasks under-
neath a vehicle while the engine is running. Be sure
the vehicle engine is off and the keys are removed
from the ignition.
Safety
CAUTION
Spicer 10 Series™ Driveshaft assemblies can weigh in
excess of 100 pounds (46 kilograms). Be sure to use proper
lifting techniques when handling Spicer 10 Series™ Driveshaft assemblies. More than one person may be needed
when handling driveshaft assemblies.
8. ALWAYS use support straps to prevent the driveshaft
from falling out of the vehicle during the removal and
installation process.
Note: This manual does not discuss the removal and installa-
tion of Spicer 10 Series™ Driveshaft assemblies from
the vehicle. It only covers the disassembly and reassembly of component parts of the driveshaft assembly.
Please refer to the original-equipment manufacturer’s
service documentation for removal and installation procedures.
9. NEVER heat components, and never use sledgeham-
mers or floor jacks to remove the driveshaft from the
vehicle.
Note: For driveshaft applications that have pillow blocks,
dampers, parking brakes, or retarders, refer to these component manufacturers’ or the original equipment manufacturer’s
service manuals for the proper procedures. NEVER perform
any unauthorized procedures that will change the disconnected properties of Spicer products.
3. NEVER perform service or maintenance tasks under-
neath a vehicle that is not on a level or flat surface.
4. NEVER work on a driveshaft without blocking the
vehicle wheels and releasing all parking brakes.
5. ALWAYS wear gloves when handling parts with
sharp edges or abrasive surfaces.
6. NEVER lift a vehicle without the appropriate weight-
rated vehicle-lift equipment. Always properly support
the vehicle with appropriate weighted support equipment.
7. NEVER remove a driveshaft from a vehicle without
keeping the transmission in neutral.
WARNING
ROTATING DRIVESHAFTS
• Rotating auxiliary driveshafts are dangerous. You
can snag clothes, skin, hair, hands, etc. This can
cause serious injury or death.
• Do not go under the vehicle when the engine is running.
• Do not work on or near an exposed shaft when
engine is running.
• Shut off engine before working on power take-off or
driven equipment.
• Exposed rotating driveshafts must be guarded.
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Component Safety
Safety
Driveline
WARNING
Failure to replace damaged driveline components can cause
driveline failure, which can result in separation of the driveline
from the vehicle. A separated driveline can result in property
damage, serious personal injury, or death.
Reassembly of a driveline out of original phase can cause
vibration and failure of the driveline and attaching components. Driveline failure can result in separation of the driveline
from the vehicle, resulting in property damage, serious personal injury, or death.
Driveshaft assemblies can weigh in excess of 100 pounds (46
kilograms). Be sure to use proper lifting techniques when
handling driveshafts. More than one person may be needed
when handling driveshaft assemblies.
CAUTION
Never heat components, never use sledge hammers, and
never use floor jacks to disassemble driveshafts. This can
result in damaged, weakened, or bent components.
End Fitting
WARNING
Failure to torque bolts to specification can cause driveline failure, which can result in separation of the driveline from the
vehicle. A separated driveline can result in property damage,
serious personal injury, or death.
CAUTION
Use a journal locator to avoid nicking journal cross trunnions
or damaging oil seal slingers.
If a bearing assembly or journal cross is worn or damaged,
the universal joint assembly must be replaced.
Be sure the snap rings are properly seated in the snap ring
grooves.
Slip Member
WARNING
Excessive radial looseness in the slip member assembly can
cause imbalance or vibration in the driveshaft. Imbalance or
vibration can cause components to wear, which in turn can
result in separation of the driveline from the vehicle. A separated driveline can cause property damage, serious personal
injury or death.
Yoke (Includes Slip Yoke, Yoke Shaft, and Tube
Yoke)
A loose end-fitting can result in driveline failure, which can in
turn lead to separation of the driveline from the vehicle. A separated driveline can lead to property damage, serious personal injury, or death.
Universal Joint
WARNING
Excessive looseness across the end of universal joint bearing
cup assemblies can cause imbalance or vibration in the driveshaft assembly. Imbalance or vibration can cause component
wear, which can result in separation of the driveline. A separated driveline can lead to property damage, serious personal
injury, or death.
DO NOT reuse bolts or use inferior grade bolts. Reuse of bolts
and/or use of inferior grade bolts can cause driveline failure,
which can result in separation of the driveline from the vehicle. A separated driveline can result in property damage, serious personal injury, or death.
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WARNING
A loose or damaged slip yoke seal allows contaminants to
invade the slip member assembly. Invasion of contaminants
into the slip member assembly can degrade the grease, and
damage slip member components, which can result in driveline separation. A separated driveline can result in property
damage, serious personal injury, or death.
DO NOT deform yoke cross holes by removing excessive
metal. Raised metal or deformed yoke cross holes can be a
cause of cross and bearing failure, which can result in separation of the driveline from the vehicle. A separated driveline can
result in property damage, serious personal injury, or death.
Yoke shaft assemblies can weigh in excess of 50 pounds
(23 kilograms). Be sure to use proper lifting techniques when
handling yoke shafts.
Safety
Tubing
WARNING
Bent or dented tubing can cause imbalance or vibration in the
driveshaft assembly. Imbalance or vibration can cause component wear, which can result in separation of the driveline
from the vehicle. A separated driveline can result in property
damage, serious personal injury, or death.
CAUTION
Do not bend or dent the tube when handling or servicing
driveshaft.
Midship Nut
WARNING
DO NOT reuse the midship nut. Reuse of the midship nut can
cause driveline failure, which can result in separation of the
driveline from the vehicle. A separated driveline can result in
property damage, serious personal injury, or death.
DO NOT touch or disturb the micro-encapsulated adhesive
found on the midship nut threads. Doing so may initiate the
curing process and impair the installation of the nut. Premature curing of the micro-encapsulated adhesive will result in
the improper installation of the midship nut. Improper installation of this nut can cause driveline failure, which can result
in a separation of the driveline from the vehicle. A separated
driveline can result in property damage, serious personal
injury, or death.
Center Bearing
WARNING
Loose center bearing bracket bolts can result in driveline failure, which can result in separation of the driveline from the
vehicle. A separated driveline can result in property damage,
serious personal injury, or death.
Damaged center bearings or center bearing components can
cause imbalance or vibration in the driveshaft assembly.
Imbalance or vibration can cause component wear, which can
result in separation of the driveline from the vehicle. A separated driveline can result in property damage, serious personal injury, or death.
Foreign Material
WARNING
Build-up of foreign material, excessive paint, or undercoating
on a driveshaft can cause imbalance or vibration in the driveshaft assembly. Imbalance or vibration can cause component
wear, which can result in separation of the driveline from the
vehicle. A separated driveline can result in property damage,
serious personal injury, or death.
A contaminated slip member can result in separation of the
driveline from the vehicle. A separated driveline can result in
property damage, serious personal injury, or death.
Hardware
WARNING
Safety
Failure to torque the midship nut to required specifications
can cause driveline failure, which can result in separation of
the driveline from the vehicle. A separated driveline can result
in property damage, serious personal injury, or death.
A loose midship nut can result in driveline failure, which can
result in separation of the driveline from the vehicle. A separated driveline can result in property damage, serious personal injury, or death.
Loose, missing, or damaged bearing retainers or stamped
straps, retaining bolts, nuts, end fitting tangs, snap rings, or
rotating bearing cups can result in driveline failure. A separated driveline can lead to property damage, serious personal
injury, or death.
DO NOT reuse bolts, straps, nuts, or damaged bearing retainers, or use inferior grade bolts. Reuse of bolts, straps, nuts,
or damaged bearing retainers, or use of inferior grade bolts,
can cause driveline failure, which can result in separation of
the driveline from the vehicle. A separated driveline can result
in property damage, serious personal injury, or death.
CAUTION
If loosening or removing bolts, always install a new strap and
bolts and torque bolts to specification.
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Safety
Lubrication (When Applicable)
WARNING
A missing, loose, or fractured grease zerk (nipple) fitting or
plug eliminates the ability to lubricate the universal joint.
Improper or inadequate lubrication can cause driveline failure,
which can result in separation of the driveline from the vehicle. A separated driveline can result in property damage, serious personal injury, or death.
Improper lubrication techniques can cause driveline failure,
which can result in separation of the driveline from the vehicle. A separated driveline can result in property damage, serious personal injury, or death.
A missing, loose, damaged, or fractured plug or grease zerk
(nipple) fitting can allow contaminants to invade the universal
joint. Invasion of contaminants into the universal joint can
degrade grease and cause universal joint damage, which can
result in separation of the driveline from the vehicle. A separated driveline can result in property damage, serious personal injury, or death.
Incompatible greases that are applied to universal joints and/
or slip members can result in driveline failure and can result in
separation of the driveline from the vehicle. A separated driveline can result in property damage, serious personal injury, or
death.
Hand tightening of grease zerk (nipple) fittings or plugs is
NOT recommended. Failure to torque grease zerk (nipple) fittings to specifications can result in separation of the driveline
from the vehicle. A separated driveline can cause property
damage, serious personal injury, or death.
CAUTION
In cold temperatures, be sure to drive the vehicle immediately
after lubrication. This activates the slip spline and removes
excess grease. Failure to do so could cause excess grease to
stiffen in the cold weather and force the plug out. The end of
the spline would then be open to collect contaminants and
cause the spline to wear and/or seize.
All slip yoke and universal joint seals should be completely
purged.
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Inspection
Inspection
Spicer 10 Series™ Driveshafts should be carefully inspected
at recommended original-equipment manufacturer’s service
intervals and/or at Spicer recommended lubrication intervals
as shown in the Lubrication section on page 11.
End Fitting Inspection
This information refers to axle, transmission, transfer case,
and center bearing end fittings. Please refer to the End Fitting
information in Component Safety on page 2.
1. Visually inspect all end-fitting retaining nuts or bolts
for any gaps or looseness between mating surfaces.
If gaps are present, consult transmission, axle, or
transfer case original-equipment manufacturer’s service and maintenance manual for proper fastener
specifications. If looseness is evident between the
nut, yoke, or center bearing, take the driveshaft to a
qualified driveshaft facility for further inspection and
repair.
2. Check all end fittings for looseness. Grasp the end
fitting with both hands and try to move it vertically
and horizontally to feel any looseness.
3. Grasp the end fitting with both hands and rotate left
to right, feeling for play and backlash. There should
not be any movement in the end fittings relative to
the output or input shafts to which they are connected. If looseness is evident, consult transmission,
axle, or transfer case original-equipment manufacturer’s service and maintenance manuals for proper
end fitting to shaft specifications.
Inspection
4. Visually inspect for:
• damaged half round bearing straps
• loose bearing strap bolts
• loose companion flange bolts and nuts
• damaged or worn tangs on end fittings
• damaged or missing snap rings
• rotating bearing cups
If any of these conditions are present, component replacement is necessary. Refer to the original-equipment manufacturer’s recommendations for removal instructions.
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Inspection
Bearing Plate (Full Round) Yoke Inspection
Please refer to the End Fitting information in the Component
Safety section on page 2.
1. Refer to original-equipment manufacturer for
removal of the driveshaft from the vehicle.
2. Place the driveshaft in v-blocks to remove the cross
and bearing assemblies. Completely remove the
cross and bearings from the yokes at both ends of
the driveshaft using a universal joint removal tool.
Next, disassemble the bearing assemblies from the
slip yoke (and flange yoke, where applicable), using
a tool kit.
4. Check the yoke lug cross holes with a No-Go Wear
Gauge, and then use a Spicer Alignment Bar to
inspect for damage by sliding through both cross
holes simultaneously.
The alignment bar will identify yoke lugs that have
taken a set because of excessive torque. The raised
metal or distorted lugs can be a cause of premature
cross and bearing problems.
5. If, after proper cleaning of the cross holes, the alignment bar will not pass through both cross holes
simultaneously, the yoke lugs are distorted, and the
yoke or yokes should be replaced.
3. Clean the cross holes on the yoke, and inspect the
cross hole surfaces for damage or raised metal.
Raised metal or fretting can be removed from yoke
cross holes with a fine-toothed file and/or emery
cloth.
WARNING
DO NOT deform yoke cross holes by removing excessive
metal. Raised metal or deformed yoke cross holes can
cause cross and bearing failure, which can result in separation of the driveline from the vehicle.
6
Inspection
Quick Disconnect™ (Half Round) End Yoke Inspection
Please refer to the End Fitting information in the Component
Safety section on page 2.
1. Remove the universal joint assembly from the end
yoke, and clean the cross hole surfaces for inspection.
2. Inspect the cross hole surfaces for damaged or
raised metal. Raised metal or fretting can be
removed from yoke cross holes with a fine-toothed
file and/or emery cloth.
WARNING
DO NOT deform yoke cross holes by removing excessive
metal. Raised metal or deformed yoke cross holes can
cause cross and bearing failure, which can result in separation of the driveline from the vehicle.
Inspect the bearing caps for any indication of rotation within the cross holes. If rotation is apparent,
the yoke should be replaced.
3. Check the yoke for cross hole alignment using the
Spicer alignment gauge. Place the correct bushing in
each lug ear, allowing a .030" (.75 mm) to .060"
(1.5 mm) clearance between the tang and the bushing.
4. Assemble bearing straps and bolts, tightening bolts
a minimum of 30 lbs. ft. (41 N•m). Insert the alignment bar into one bushing. If the bar enters and
passes through the opposite bushing, alignment is
correct. If the alignment bar will not enter the opposite bushing, re-inspect for yoke seat burrs.
Inspection
5. If, after proper cleaning, the alignment bar still does
not pass through both bushings, the yoke lugs are
distorted, and the yoke should be replaced.
7
Universal Joint Inspection
Inspection
Please refer to the Universal Joint information in the Component Safety section on page 2.
1. Check for excessive looseness between the ends of
the universal joint bearing cup assemblies and trunnions.
2. Grasp the inboard yoke on the driveshaft with both
hands and attempt to move the yoke horizontally and
vertically. There should be less than .006" (.15 mm)
movement in the universal joint relative to the
inboard or outboard yokes. If looseness is greater
than .006" (.15 mm) in either direction, the universal
joint must be replaced. See Disassembly and Reassembly on page 16.
Re-lubable Style Universal Joints
1. With re-lubable style universal joints, check for the
presence of all grease zerk (nipple) fittings. Grease
zerk (nipple) fittings should not be missing, loose, or
fractured.
2. If a grease zerk (nipple) fitting is loose, tighten it to
required specifications. See the Universal Joint
Grease Zerk (Nipple) Fitting and Plug Torque table on
page 26.
3. If a grease zerk (nipple) fitting is fractured or missing, the entire universal joint must be replaced. Refer
to Disassembly and Reassembly on page 16 for
removal and replacement instructions.
Permanently Greased Plug Style Universal Joints
Please refer to the Universal Joint information in Component
Safety on page 2.
1. Permanently greased plug style universal joints have
a plug rather than grease zerk (nipple) fittings. Make
sure the plug is not missing, loose, or fractured. If
the plug is loose, tighten it to required specifications.
See the Universal Joint Grease Zerk (Nipple) Fitting
and Plug Torque table on page 26.
2. If a plug is missing or fractured, the entire universal
joint must be replaced. Refer to recommendations in
the Disassembly and Reassembly on page 16 for
removal and replacement instructions.
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