Spicer Driveshafts User Manual
Spicer
®
Driveshafts
Service Manual
Spicer® Life Series
DSSM0100
December 2010
Table of Contents
Inspection Procedures
Inspection Warnings and Cautions . . . . . . . . . . . . . . . . . .1
Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Slip Member Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Tubing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Center Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Lubrication
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Recommended Lubricants for Relubable Universal Joints and
Slip Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Grease
Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Slip Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Center Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Removal
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . .14
Driveshaft Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Grease Zerk
Slip Member Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Removal and Installation . . . . . . . . . . . . . . .16
Installation
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . .21
Universal Joint - Snap-Ring Style. . . . . . . . . . . . . . . . . . .22
Universal Joint - Spring Tab Style . . . . . . . . . . . . . . . . . .24
Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Slip Member and Boot . . . . . . . . . . . . .
Driveshaft
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . .26
Glossary
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
For additional service information, go to www.dana.com or
call 1-877-777-5360.
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General Information
General Information
Spicer Life Series™ Features and Benefits
Note: Spicer Life Series™ driveshafts are found on vehicles
throughout the world. Therefore, this manual includes
worldwide terminology.
This manual encompasses inspection, lubrication, removal
and installation procedures for Spicer Life Series™ 55, 70, 90,
100, 140, 170 and 250 driveshaft assemblies.
Important Features of a Spicer Life
Series™ Driveshaft
Spicer offers a complete range of driveshaft solutions to meet
the full spectrum of needs in medium and heavy duty applications. The Spicer Life Series™ driveshafts have been designed
and developed to stand up to the wear and tear of heavy hauling tasks. They are the first driveshafts in the industry to be
compatible with advancing powertrain specifications for
higher engine torque and lower axle ratios. No one does more
than Spicer in meeting the needs of the marketplace.
Spicer Life Series™ driveshafts offer:
• Longer life
• Lower lifetime management
• Increased strength for higher engine torque and
lower axle ratios
• Smaller driveshaft rotating diameter
General Information
Spicer Life Series™ award winning* universal joint kits are
specifically designed to give extended driveshaft life. Flatended needle bearings are used to withstand oscillating loads
while the driveshaft is rotating and to eliminate skewing in the
bearing cup. Thrust washers significantly reduce end galling
on trunnion ends and lower universal joint operating temperature. Synthetic rubber seals and plastic seal guards provide
lubricant retention and help prevent the entry of foreign material, significantly increasing universal joint life. The centrally
located grease zerk (nipple) fitting increases the strength of
the journal cross and allows more torque carrying capacity.
High-strength steel tubing is used to provide maximum
torque carrying capacity at minimum practical weight.
Increased tube diameter allows a higher critical speed and
longer one-piece driveshafts. This increased stiffness also
improves noise, vibration and harshness. New slip member
booting or alternative seal can offers better protection against
environmental contaminants, increases component life, and is
lubricated for the life of the product.
The new integral tube sleeve and yoke shaft design, found on
heavy duty Spicer Life Series™ designs, along with larger
diameter involute splines, creates greater strength and torsional stiffness with less weight. This new design leads to
improved balance and less slip effort, resulting in reduced
noise and vibration for the entire driveshaft system. Spicer
Glidecote®, found in all slip member assemblies, reduces
friction, thereby lowering thrust loads under high torque. This
nylon coating also prevents spline wear and extends life.
A driveshaft that transmits high torque loads must be durable
and strong. Spicer uses forged steel and high strength cast
yokes to provide the necessary rigidity to maintain bearing
alignment under torque loads. Spicer Life Series Quick Disconnect™ end yokes reduce the time to remove or install the
driveshaft, equating up to a 75% labor savings for service.
Applications requiring flange connections, S.A.E., DIN and
cross-serrated T-Flanges are available. A new cold-formed,
bearing retainer provides structural rigidity and reduces bearing movement which may result from overloading.
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Warnings and Cautions
Spicer Life Series™ Inspection Warnings and Cautions
Before You Get Started
1. ALWAYS wear safety glasses when performing
maintenance or service. Failure to wear safety
glasses can result in personal injury and/or partial or
complete vision loss.
2. NEVER go under a vehicle while the engine is running. Be sure the vehicle's engine is off, and keys are
removed from ignition.
3. NEVER go under or work on a vehicle that is not on a
level or flat surface.
4. NEVER work on a driveshaft without blocking the
vehicle's wheels and releasing all parking brakes.
See warning below.
5. NEVER lift a vehicle without the appropriate weightrated, vehicle-support equipment.
6. NEVER REMOVE a driveshaft from the vehicle without keeping the vehicle's transmission in neutral.
See above warning.
7. CAUTION – Spicer Life Series™ driveshaft assemblies can weigh in excess of 100 pounds (46 kilograms). Be sure to use proper lifting techniques
when handling Spicer Life Series™ driveshafts. More
than one person may be needed when handling
driveshaft assemblies.
8. ALWAYS use support straps to prevent the driveshaft from falling, causing injury and/or damage during the loosening or removal of any driveshaft
hardware.
9. NEVER heat components or use sledgehammers or
floor jacks to remove the driveshaft from vehicle.
Note: For driveshaft applications that have pillow blocks,
dampers, parking brakes or retarders, refer to these
component manufacturers' or the original equipment
vehicle manufacturers' service manuals for proper procedures.
Driveline
WARNING
WARNING: Reassembly of a driveline out of original phase
can cause vibration and failure of the drivline and attaching
components.
WARNING: 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.
WARNING: Never heat components, never use sledge hammers, and never use floor jacks to disassemble driveshafts.
This can result in damaged, weekened, or bent components.
End Fitting
WARNING
WARNING: 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
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 drivline.
WARNING: DO NOT reuse bolts or use inferior grade bolts.
Reuse of bolts and/or use of inferior bolts can cause driveline
failure, which can result in separation of the drivline from the
vehicle.
WARNING: Failure to torque bolts to specification can cause
driveline failure, which can result in separation of the driveline
from the vehicle.
CAUTION: Use a journal locator to avoid nicking journal cross
trunnions or damaging oil seal slingers.
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.
1
CAUTION: If a bearing assembly or journal cross is worn or
damaged, the universal joint assembly must be replaced.
CAUTION: Be sure the snap rings are properly seated in the
snap ring grooves.
Warnings and Cautions
Slip Member
WARNING
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)
WARNING: A loose or damaged slip yoke seal allows contam-
inants 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.
WARNING: 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 driveline from the vehicle.
WARNING: Yoke shaft assemblies can weigh in excess of 50
pounds (23 kilograms). Be sure to use proper lifting techniques when handling yoke shafts.
WARNING: DO NOT touch or disturb the micro-encapsulated
Warnings and Cautions
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 improper installation of the midship nut. Improper
instsallation of this nut can cause driveline failure, which can
result in separation of the driveline from the vehicle.
WARNING: Failure to torque the midship nut to required
specifications can cause driveline failure, which can result in
separation of the driveline from the vehicle.
WARNING: A loose midship nut can result in driveline failure,
which can result in separation of the driveline from the vehicle.
Center Bearing
WARNING
WARNING: Loose center bearing bracket bolts can result in
driveline failure, which can result in separation of the driveline
from the vehicle.
WARNING: 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.
Tubing
WARNING
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.
CAUTION: Do not bend or dent the tube when handling or
servicing driveshaft.
Midship Nut
WARNING
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.
Foreign Material
WARNING
WARNING: Build-up of foreign material, excessive paint, or
undercoating on a driveshaft can cause imabalnce or vibration
in the driveshft assembly. Imbalance or vibration can cause
component wear, which can result in separation of the driveline from the vehicle.
WARNING: A contaminated slip member can result in separation from the vehicle. A separated driveline can result in property damage, serious personal injury or death.
Hardware
WARNING
WARNING: Loose, missing, or damaged bearing retainers or
stamped straps, retaining bolts, nuts, end fitting tangs, snap
2
Warnings and Cautions
rings, or rotating bearing cups can result in driveline failure.
A separated driveline can lead to property damage, serious
personal injury, or death.
WARNING: DO NOT reuse bolts, straps, nuts, or damaged
bearing retainers or inferior grade bolts. Reuse of bolts,
straps, nuts, or damaged bearing reatiners, or use of inferior
grade bolts can cause driveline failure.
CAUTION: If loosening or removing bolts, always install a
new strap and bolts and torque bolts to specification.
Lubrication
WARNING
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.
WARNING: Improper lubrication techniques can cause driveline failure, which can result in separation of the driveline
from the vehicle.
CAUTION: All slip yoke and universal joint seals should be
completely purged.
WARNING: 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.
WARNING: 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.
WARNING: Hand tightening of grease zerk (nipple) fitting or
plugs is NOT recommended. Failure to torque grease zerk
(nipple) fittings to specifications can result in separation of
the driveline from the vehicle.
WARNING: Maximum grease gun pressure should not
exceed 60 psi. Excessive grease gun pressures may cause
seal damage.
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.
3
Inspection Procedures
Inspection Procedures
Visually inspect all input and output end-fitting retaining nuts
or bolts for any gaps between mating surfaces. If gaps are
present, consult transmission, axle or transfer case original
equipment manufacturers' service and maintenance manuals
for proper fastener specifications.
Visually inspect for damaged bearing retainers or stamped
straps, loose bearing retainer bolts or strap bolts, loose companion flange bolts and nuts, loose or missing spring tabs or
spring tab bolts, damaged tangs on end fittings, damaged or
missing snap rings, and rotating bearing cups.
If any of these situations are evident, replacement of the components is necessary. Refer to the removal and installation
sections of this manual for proper replacement procedures.
Universal Joints
Note: The following procedures are to be performed prior to
any lubrication of universal joints or slip members. The
addition of lubricant can mask the looseness in a componet that is beginning to show wear and may be in
need of replacement.
1. Check for excessive looseness across the ends of
the universal joint bearing cup assemblies and trunnions. Take hold of the inboard yoke on the driveshaft with both hands. Try to move the yoke
vertically and horizontally.
There should be less than .006" (.15mm) movement
in the universal joint relative to the inboard or outboard yokes. If looseness is greater than .006"
(.15mm), the universal joint kit may need to be
replaced.
Inspection Procedures
IMPORTANT
Note: If the movement of the driveshaft is greater than .006",
the carrier assemblies input shaft and/or output shaft
ends play must be checked to make sure they are within
specification. Endplay readings that are out of specification must be corrected before an accurate driveshaft
reading can be taken. Refer to the Input/Output Shaft
Endplay Inspection procedure.
WARNING
Excessive looseness across ends 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 from the vehicle.
Check Input Shaft End-Play (Forward Axle)
a. Position dial indicator at yoke end of input shaft.
b. Push on input shaft and zero dial indicator.
c. Using pry bar, move input shaft axially and measure/
record end-play.
Add shims to increase end-play.
Note: Input and output shaft endplay specifications will vary
between model. Refer to manufacturer’s service manual
for correct endplay specifications.
4
Inspection Procedures
Remove shim to decreased end-play.
Measured end-play (Step 3) 0.015” – 0.015”
Desired end-play (New Parts) 0.003” to 0.007”
Remove shims to provide desired
end-play
Check Output Shaft End-Play (Forward Axle)
a. Position dial indicator at yoke end of input shaft.
b. Push on output shaft and zero dial indicator.
c. Using pry bar, move input shaft axially and measure/
record end-play.
3
2
0.012” to 0.008”
- If grease zerk fitting is loose, tighten to required
specifications.
- If grease zerk fitting is fractured, replace grease zerk
fitting and tighten to required specifications.
- If grease zerk fitting is missing, the entire universal
joint kit needs to be replaced.
- If the plug is loose, tighten to required specifications.
- If a plug is missing or fractured, the entire universal
joint kit needs to be replaced.
Slip Member Assembly Inspection
1. Check the slip member assembly for excessive radial
looseness. Using a dial indicator, take hold of the
tubing near the slip member with both hands and try
to move vertically, up and down relative to the
ground.
1
Note: The output yoke can be installed when taking end-play
measurements.
d. Correct end-play for new assembly is .001" to .015".
Grease Zerk Inspection
Check for presence of all grease zerk fittings. Grease zerk fittings should not be loose, fractured or missing.
2. Arrange dial indicator with magnetic base one-quarter inch (1/4") from the driveshaft’s tube weld. Dial
indicator should be firmly mounted on the tube so
that no movement of the dial indicator base is
allowed.
3. Extend dial indicator arm from the base, across the
slip member boot, allowing the dial indicator to contact the yoke shaft tube one quarter inch (1/4") off
the opposite side of the boot from where the magnetic base is mounted. Dial indicator’s arm should be
running parallel to the driveshaft.
5
Inspection Procedures
4. Apply effort perpendicular to shaft axis making note
of total indicator travel. Allowable indicator travel is
.000-.012 in.
WARNING
Excessive radial looseness 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.
6. Visually inspect for the presence of the grease zerk
fitting, if applicable, on the slip yoke.
a. If grease zerk fitting is loose, tighten to required
specifications. (See Table C.)
b. If grease zerk fitting is missing or fractured, the
slip members may need to be replaced.
Table C - Slip Member Grease Zerk Fitting Specifications
Inspection Procedures
5. For an inboard and outboard slip yoke assembly
design, check to be sure the slip yoke welch plug is
not loose, missing or damaged.
If any of these situations are evident, replacement of
the slip yoke and professional rebalancing of the
driveshaft is necessary.
Thread
Size
0.25"-28" 3.5-6.2 31-55
7. Check the slip yoke seal. Make sure the seal is properly attached to the slip yoke and is not loose or
damaged.
Permanently Lubricated Style
Check the yoke shaft boot. Make sure the boot is properly
attached to the yoke shaft assembly and splined sleeve. Visually inspect for boot tears, punctures, loose clamps and clamp
damage.
If any of these situations are evident, replace damaged components and measure slip joint movement.
Zerk
Nm
Torque
IN. LB.
6
Tubing Inspection
1. Check the driveshaft for bent or dented tubing. If
either of these situations is evident, replacement of
the complete driveshaft assembly or tube is necessary.
2. Make certain there is no buildup of foreign material
on driveshaft.
If found, buildup should be removed carefully to
avoid damaging the driveshaft.
a. When removing dirt or mud, rinse with water.
b. When removing tar or undercoating, use min-
eral spirits or any appropriate solvent.
Center Bearings Inspection
Inspection Procedures
1. Visually inspect all center bearings, end-fitting midship nuts for any gaps between the mating surfaces.
Note: Be sure to repeat steps 2 and 3 for all center bearing
end fittings for broken back and backlash.
2. Inspect the center bearing bracket bolts for looseness.
Note: If looseness is evident, retighten center bearing bracket
bolts. Consult the vehicle manufacturers’ specifications
for proper bolt torque. Check the alignment of the
bracket before tightening the bolts. Bracket should not
be skewed.
3. Visually inspect the center bearing rubber cushion
for damage. Make sure the slingers are not rubbing
against the rubber cushion. Verify that the rubber
cushion is properly seated in the metal bracket.
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Lubrication Warnings
Spicer Life Series™ Lubrication Warnings and Cautions
Before You Get Started
1. ALWAYS wear safety glasses when performing
maintenance or service. Failure to wear safety
glasses can result in personal injury and/or partial or
complete vision loss.
2. NEVER go under a vehicle while the engine is running. Be sure the vehicle's engine is off, and keys are
removed from ignition.
3. NEVER go under or work on a vehicle that is not on a
level or flat surface.
4. NEVER work on a driveshaft without blocking the
vehicle's wheels and releasing all parking brakes.
See warning below.
5. NEVER lift a vehicle without the appropriate weightrated, vehicle-support equipment.
6. NEVER REMOVE a driveshaft from the vehicle without keeping the vehicle's transmission in neutral.
See above warning.
7. CAUTION – Spicer Life Series™ driveshaft assemblies can weigh in excess of 100 pounds (46 kilograms). Be sure to use proper lifting techniques
when handling Spicer Life Series™ driveshafts. More
than one person may be needed when handling
driveshaft assemblies.
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.
Incompatible lubricants/greases which are applied to universal joints and/or slip members, can result in failure of
the driveline and can result in separation of the driveline
from the vehicle.
To prevent serious eye injury, always wear safety glasses
when performing maintenance or service. Failure to wear
safety glasses could result in serious personal injury, and/
or partial or complete vision loss.
Lubrication
8. ALWAYS use support straps to prevent the driveshaft from falling out of vehicle during the removal
and installation process.
9. ALWAYS wear protective gloves when applying
grease to slip joints or other driveshaft components.
10. NEVER heat components or use sledgehammers or
floor jacks to remove the driveshaft from vehicle.
Note: For driveshaft applications that have pillow blocks,
dampers, parking brakes or retarders, refer to these
component manufacturers' or the original equipment
vehicle manufacturers' service manuals for proper procedures.
WARNING
Failure to release all parking brakes and failure to place
transmission in neutral can result in torque being applied to
the driveshaft. Disconnecting a driveshaft with applied
torque can result in property damage, serious personal
injury or death.
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