sae ii ee UNIVERSAL JOINTS TROUBLE SHOOTING INFORMATION = eS ie 1a Tae V51069 PgtINTRODUCTION Universal joint failure, as a rule, are of a progressive nature, which, when they occur, generally accelerate rapidly resulting in a mass of melted trunnions and bearings. Some recognizable signs of universal joints deterioration are: 1. Vibrations - Driver should report to maintenance. 2. U-Joint Looseness - End play across bearings. 3. U-Joint discoloration due to excessive heat build-up. 4. Inability to purge all four trunnion seals when re-lubing U-joint. Item 2. thru 4. should be checked at re-lube cycle and if detected reported to the maintenance supervisor for investigation. Experience with universal joint failures has shown that a significant majority are related to lubricating film breakdown. This may be caused by a lack of lubricant, inadequate lube quality for application, inadequate initial lubrication or failure to lubricate properly and often enough. Failure which are not a result of lubrication film breakdown are associated with the installation, angles and speeds and manufacturing discrepancies. Drive shaft failure through torque, fatigue and bending are associated with overload, excessively high U-joint angles and drive shaft lengths excessive for operating speeds. The trouble shooting chart in this bulletin is intended to provide service people with an aid to enable them to associate complaints with some of the probable causes and probable corrections. Which through normal machine maintenance and recognition of discrepancies may enable them to make necessary corrections to ward off a serious breakdown. DRIVE SHAFT TORQUE - Twisted drive shaft tube? - Broken yoke shat? - Broken journal cross? Usually a result of torque overload - How much torque can be generated in your application? Pg2Universal Joints - Troubleshooting Chart Problem Low Mileage U-joint Failures Repeat U-Joint Failure End Galling of Cross Trunnion and Bearing Cup Problem Causes Lack of lubrication Inadequate intial lubrication Inadequate grease quality for application Inadequate relube cycles for application environment Failure to lubricate properly Defective or worn seals Continuous operation at high angle - high speed Excessive continuous running load End galling of crossing trunnion and bearing cup Excessive U-bolt torque on retaining nuts - pinching rollers Lack of lubrication Inadequate initial lubrication Inadequate grease quality for application Inadequate relube cycles for application environment Failure to lubricate properly Defective or worn seals Yoke distortion due to initial failure Continuous operation at high angle ~ high speed Excessive continuous running load End galling of cross trunnion and bearing cup. Continuous operation at high angle high speed Contamination (abrasion) Lubricating film breakdown Excessive thrust fit Yoke cross hole alignment Yoke lug face squareness Pg3 1,8,11 16Problem Frettage (also false brinnelling, wear oxidation, friction oxidation, and chatfing fatique).. Bearing race ©.D. Seizure in Yoke Cross Holes Slip Spline Seizures Slip Spline Galling Problem Causes Contamination (abrasion) Lubricating Film Breakdown No u-joint operating angle Long shaft with loose u-joint Thrust fit and unbalance Roller Lock Roller Skewing Excessive U-bolt torque on retaining nuts = pinching rollers Frettage corrosion due to yoke working load. Lack of lubrication Inadequate initial lubrication inadequate grease quality for application Inadequate relube cycles for application envrnntment Failure to lubricate properly Contamination (abrasion) Lubricating film breakdown Galling (adhesive wear) Slip member working in extreme Extended position Excessive loose O.D. fit Excessive torque load for u-joint and driveshaft size Contamination (abrasion) Lubricating film breakdown Slip member working in extreme extended position Male spline head engagement length too short for application Excessive torque load for u-joint and driveshaft size Pg4 Remedy 1,8,11 1,5,6,8 10 18,22,25,26 11,13 11,1213 26 1,68 1,6 5,8,14 15 1,68 15 16,17Problem Slip Spline O.D. Wear at Extremities and at 180 D Slip Spline Shaft or Tube broken in Torsion Shaft Broken in Bending Tube Split in Longitudinal Seam Weld Tube Circle Weld Failure Yoke Broken in Hub Problem Causes Slip member working in extreme extended position Excessive loose .D. fit Male spline head engagement length too short for application Excessive torque load for u-joints and driveshaft size Improper slip spline shaft neck Tunout - stress riser Inadequate radius at slip spline shaft. Neck runout - stress riser Tube size inadequate Defective or worn part Driveshaft too long for operating speeds. Bending fatique due to secondary couple loads Defective or worn part Excessive torque load for u-joints and driveshatt size Defective circle weld Balance weight too close to circle weld Balance weight located in apex of weld yoke lub area. Excessive torque load for u-joints and driveshaft size Bending fatigue due to secondary couple loads Inadequate hub and radius for application Remedy 15 11,32 5,19 "1 5,17 5,19 " 18,19 " 5,19 W " " 20Problem Yoke Brake at Ear Tip Broken Cross or Cups Needle Rollers Brinelled into cups and Cross Trunnion Shaft Support Brg. Failure Shaft Support Rubber Insulator failure Transmission Extension Bell Housing and Clutch Housing Failures Problem Causes Defective forging or casting Mating yoke lub interference at full jounce and rebound Improper shaft length and slip Excessive torque load for u-joints and driveshaft size Excessive torque load for u-joint and driveshaft size Lack of lubrication Inadequate initial lubrication Defective or worn seals Contamination (abrasion) Defective or worn part Shaft support brg. misaligned - interference with slinger Worn universal joints Continuous running u-joint angles - too large Unequal u-joint angles Driveshaft balance and straightness Damaged Driveshaft tube Runout on drive and driven support shafts Excessively loose u-joint for operating speed and length Loose 0.0. fit on slip spline Driveshaft too long for speed - operating in critical Driveshaft weight not compatible with Eng. - transmission mounting Driveshaft yoke phasing Po6 Remedy " 4,27 28 11,32 " 11,32 11,32 11,32 29 30 4 32 oo 22,31 23 18,22,25,26 11,32 18,19 18,24 33Problem Vibrations Low Gear Shudder Vibrations in Short Speed Ranges under Full Drive or Full Coast Vibrations Under Light Loaded Conditions Problem Causes Inadequate torque on caps screws retaining brg. plate Worn universal joints Continuous running u- too large Unequal u-joint angles Driveshaft balance and straightness Damaged driveshaft tube Runout on drive and driven support shafts Excessively loose u-joint for operating speed and length Loose ©.D. fit on slip spline Driveshaft too long for speed - operating in critical Driveshaft weight not compatible with Eng, - transmission mounting Driveshaft yoke phasing int angles - Secondary couple load reaction at shaft support brg. Torsional Excitation Inertia Excitation Po7 32 22 22,31 23 18,22,25,26 11,32 18,19 18,24 33 4,21,33,34 421Probable Corrections 10. 1. 12. 13. 14, 15. 16. 7. 18. 19. 20. 21 22. ‘See joint lube specs. Replace seals on new kit. Replace complete kit if used. fyoke distorted - replace. Reduce u-joint continuous running angles. Replace with higher capacity u-joint and driveshaft. Use hitemp grease. Check u-joint flex effort. If sticks, binds or grabs - replace u-joint kit. If replacement kit sticks binds or Grabs - Check yokes for span, lug squareness, cross hole alignment, etc. If excessive -replace. Clean and relubricate per lube specs, if check on components indicate they are serviceable = replace If not. No immediate fix. Use of anti-seize lubricates on bearing 0.0. initially helps. Re-align to have a minimum of one degree running angle. Replace Roller lock - replace assembly. Yoke deflections under load. Use larger joint. Use spicer "gilidecote* - slip spline Increase driveshaft assy. Length to position slip spline head towards u-joint. Check for male slip member with longer spline. Design inadequate for application. Install two piece driveshaft with shaft support brg. Use larger diameter tube. Design limitation due to axle to trans. shaft requirement. Shim drive train components to equalize u-joint angles. Straighten and balance23. 24, 25. 26. 27. 28. 29. 31. 8 35. Check with Trans. or axle mfg. - replace shaft brg. Revise power plant mounting scheme. Check u-joint flex effort looseness. ‘Torque bearing retention method to spec. Use wide angle yokes. Check installed length and adjust driveshaft length to provide proper slip conditions. Re-align mounting brkt. to frame cross member to eliminate interference. Replace u-joint kits. Replace tube. Normal wear - replace ‘Check OEM maintenance manual or alignment arrows on slip shaft for correct yoke phasing. 2 pe. - AUT driveshaft adjust shaft lengths to 50-50 or 40-60 split. Re-position shaft support bearing.