Trorfiro

Volvo Trucks North America, Inc.

Greensboro,NC USA
Date Group No.
TSI
Supp. Page
3.98 451 008 1(1)
DriveShaft PhaseAngles
All Models

Drive Shaft PhaseAngles

There are vehides wfrich have various sections of the drive shaft phased at specific
angles. Fadory set phase angles are vitally importrantto the qualrtyof the ride, the
reductionof ddve line vibrationand maior componentlife.

AcAunoN
Under no circumstances should the phasing of any
component of the drive shaft system be changed or
tamperedwith in any way. Doing so could c€rusesevere
vibration,decreasedU-iointlife and/ordamageto axles
or transmissions.

PVT|6-451-008SB USA0't328
\ztoL\ro
VolvoTrucks North America,Inc.
NC USA
Greensboro,
TSI Page
Date Group No. Supp.
This TSI ServiceBulletinreplacesTSI ServiceManual
451400, "DriveShaftsand UniversalJoints"(6.94), 3.2001 451 011 1(so)
publicationnumberPV77H51 -600SM.
DriveShaftsand UniversalJoints
All Models
DriveShaftsand UniversalJoints

w4000Gb

and serviceof drive shafts

This informationcoversdesigninformation,specifications,
and univercaljoints used on Volvovehicles.

PV776-TSP154387 usA09744
Page 2

Specifications
Drive Shaft
JointJournalCrossDimensions
Universal

Fig. 1: UniversalJoint JournalCross Dimensions

Series A B Series A B
mm tn mm tn mm tn mm tn

1600 32.54 1 9132 127.OO 5 1800HD 42.47 1 43/64 155,97 6 9/64

1610 32.15 1 17/64 127,OO 5 1810 32.94 1 19164 1 8 4 . 1 5 7 1/4

1650 26.59 1 3/64 1 3 1 . 7 6 5 3/16 1820 34.93 1 3/8 192.88 7 19132

1700 33.34 1 5/16 136.92 5 25164 1850 34.93 1 3/8 192.88 7 19/32

1710 32,94 1 19164 146.84 5 25132 1900 49.61 1 61/64 211.93 811132

1760 32.94 1 19164 159.54 6 9132

Note: Measurethe diameter"A" and the span, or length
"B" of the journal cross to determineuniversaljoint size
1800 42.86 1 11/16 159.54 6 9132 or series.
 VolvoTrucks North America,lnc. Date Group No. Page
TSI 3.2001 451 01 1 3(ao)

\- EndYoke
Half-Round Full RoundEnd Yoke
Boh Torque CapscrewTorque
Series ThreadSize Series Thread Size
Nm ft-tb Nm ft-tb

1610 (3/8) 0.37*24 68-81 5H0 1610 (5/16)0.312-24 19-35 1+26

1710 (1/2) 0.500-i20 156-176 1 1 5 - 1 3 0 1710 (3/8) 0.375-24 3845 28-4,8

1760 (1/2)0.50r'20 156-176 115-130 1760 (3/8) 0.375-24 38-65 28-4,8

1810 (1/2) 0.50G-20 15r176 1 1 5 - 1 3 0 1810 (3/8) 0.37*-24 38-€5 28-4,8

MaximumDriveShaftOperating DriveShaft,MaintenanceInter-
Angle VAIS
NormalAngles Service miles(km) Time/Month

MaximumOperatingAn- 5 000/8 000

DriveShaft rpm gles City 3
(8 000/13ooo)
5000 30-1s'
10 000/15000
4500 3"-40' On Highway 1
(16 000/24000)

4000 4o-1s'
5 000/8 000
Or/Otf Highway 3
3500 50-0' (8 0oo/13000)

3000 5"-50' ExtendedLine

Haul 50 000 (80 000) 1
2500 f4' (16111880)

2000 8'-40' 2 000/3 000

Severe Use Off
1
Highway4 x 4 (3ooo/50oo)
1500 10-30'
Page 4

DriveShafts

r
t
I
l' - ' - ' -

Fig. 2: TypicalDrive Shaftand UniversalJoint Assembly

1 Transmission 4 Center bearing 6 Seal 8 Differential

2 Yoke 5 UniversalJoint 7 Slipshaft spline
3 Drive shaft tubing

The drive shaft is a steel tube that transmits power from

the transmissionoutput shaft to the differential.To ac-
commodatevariousmodel,wheelbaseand transmission
combinations,drive shaftsdifferin length,diameterand
the type of splinedyoke. Eachshaft is installedin the
same manner.A universaljoint and splinedyoke are lo-
cated at the transmissionrear extension.The slip yoke
permitsfore and aft movementof the drive shaft as the
differentialassemblymovesup and down. The spline is
lubricatedinternallythrougha greasefitting.An oil seal
preventsleakageand protectsthe slip yoke from dust,
dirt and other harmfulmaterials.
Sincethe drive shaft is a balancedunit, it shouldbe kept
completelyfree of undercoatingand other foreignmate-
rial whichwould upsetshaft balance.
One-,two- and three-piecedrive shafts are used, de-
pendingon the total lengfih.
On modelsthat use a two-pieceor three-pieceshaft,the
shaft is supportednear its splinedend in a rubber-
cushionedball bearing(commonlyreferredto as the
centerbearing)which is mountedin a bracketattached
to a framecrossmember.The center bearingis perma-
nentlylubricatedand sealed.
 VolvoTrucks North America,Inc. Date Group No. Page

TSI 3.2001 451 011 5(30)

DriveShaftCenterBearing
\ lf replacingthe center bearing,it is not necessaryto
pack it with grease.However,chassis lubricantshould rulrEl
be packedwithinthe dust shieldsto form a dam to help xflnaT
preventwater and dirt from reachingthe bearing.The
dust shieldsare stakedinto position.

Fig. 3: CutawayView of Center Bearing

DriveShaftFunction
The basic function of the drive shaft is to transmit power
from one point to another in a smooth, continuousac-
tion. In trucks and constructionequipment,the drive
shaft is designedto send torque through an angle from
the transmissionto the a,rle (or auxiliarytransmission).
The drive shaft must operate through constantlychang-
\-_ ing relativeangles betweenthe transmissionand axle. lt
mustalso be capableof changinglengthwhile transmit-
ting torque.The axle of a vehicleis not attacheddirectly
to the frame,but ridessuspendedby springsin an irreg-
ular,floatingmotion.This meansthe drive shaft must be
able to changelengrthand operatingangleswhen going
over bumpsor depressions.This is accomplished
throughuniversalioints,which permitthe drive shaft to
operateat differentangles,and slip joints, which permit
lengtheningor shorteningof the drive shaftto take place.
Page 6

Constructionof a DriveShaft
To transmitrequiredtorque loads,the drive shaft must
be durableand strong.Forgedsteel and high-strengrth,
cast, end yoke for heavy-dutyvehiclesare used to pro-
vide the necessaryrigidityrequiredto maintainbearing
alignmentundertorque loads.
Anti-frictionbearingsare used to withstandoscillating
loads whilethe drive shaft is rotatingat high speeds.
The needlerollerbearingson the cross trunnionscarry
large loads and are used becauseof their high capacity
in a limitedspace.
The bearingassemblyinside-diameter crowningand ta-
peredthrust pads distributeload more evenlyon needle
rollerbearingsand crosstrunnionends to significantly
reduceend galling.Bearingassembliesare individually
sealed to retain lubricantsand keep foreign materialout.
lf lubricantsbecome contaminatedwith water or abrasive
material,needle rollerbearinglife is seriouslyaffected.
Abrasivematerial is a major problemfor vehiclesoperat-
ing in extremelymoistand dirty environments. To
combatthis problem,syntheticrubberseals were devel-
oped and resultedin increasedlife, ability to withstand
high temperaturesand a less criticalrelubricationcycle
for drive shafts.
Specialhigh-strengthtubing is used to providemaximum
torque carrying capacrtyat minimumpracticalweight.
Drive shafts have been developedto meet the vehicular
industryneeds.
The slidingsplinesbetweenslip joint and permanentjoint
must supportthe drive shaft and be capableof sliding
underfull torque loads.To aid in this axial or slip move-
ment, Glidecotewas developedto reduceslidingfriction,
reducingthrust underhightorque.This non-metalliccoat-
ing also preventssplinegallingand extendssplinelife.

Balancinga Drive Shaft

(All types)
Rebuildingthe drive-shaftassemblyusuallyincludesre-
placingworn cross and bearingassemblieswith a new
kit. These kits replacethe part of a drive shaft most sub-
ject to wear in operation.The potentialoff-center
conditionpresentin the cross and bearingassemblies
make it desirableto balanceevery assemblyafter in-
stallingnew cross and bearingkits. When the tubing is
bent or twistedor the tube fittingsare distorted,it will be
necessaryto replacethe drive shaft assembly.
VolvoTrucks North America,Inc. Date Group No. Page
TSI 3.2001 451 01 1 7(30)

DriveShaftAnglesand Phasing
(All types)
Properdriveshaft anglesand correctphasingof the
yokes are very importantin maintaininglong life and
quiet runningdrive shafts.
When in phase,the slip yoke lugs (ears)and tube yoke
lugs (ears)are in line. Normally,this is the ideal condi-
tion and givesthe smoothestrunningdrive shaft.There
shouldbe an alignmentarrow stampedon the slip yoke
and on the tube shaftto ensureproperphasingwhen
assemblingthese components.lf there are no alignment Fig. 4: Drive-ShaftArrows Lined Up "ln Pha:S*
marks, they should be added beforedisassemblyof the
drive shaft to ensure proper reassembly.
Be careful not to changeor remarka drive shaft assem-
bly manufacturedout-of-phasefor specialapplications.
Locate the arrows markedfor the out-of-phasedrive
shaft and do not changethem. Do not replace an out-of-
phase drive shaft with a drive shaft that is in phase.
Phasingis relativelysimpleon a two-jointset. Be sure
that the slip yoke lugs and the tube yoke lugs are in line.

Drive shaft anglesare a littlemore complicated.The U-

joint operatingangle is the angleformedby two yokes
connectedby a cross and bearing kit. There are two
kinds of U-jointangles.
The simpleone-planeanglefound in most installations
confinesall drivelineslopesto one plane,usuallythe
verticalplane.
The other type of driveshaft angle is the compoundan-
gle in two planes.This is found in drive-shaftdesigns
where offset exists in both the verticaland horizontal
planes.
High anglescombinedwith high rpm reduceU-jointlife.
Too largeand unequalU-jointanglescan causevibration Fig. 5: One-PlaneAngle DriveSnaH*
and contributeto U-joint,transmissionand differential
problems.lmproperU-jointanglesmust be corrected.
ldeally,the operatingangleson each end of the drive
shaft shouldbe equal to or within 1" of each other,have
a 3o maximumoperatingangleand haveat least 1/2 ol
1" continuousoperatingangle.
The mainfactorin determiningmaximumallowableoper-
ating anglesis rpm. As a guideto maximumnormal
operatingangles,referto "MaximumDriveShaft Operat-
ing Angle"page3.
Tubediameterand normaloperatingrpm determinemax-
imum allowabletube lengfih.lf "criticallength"is reached,
use a three-jointdrive shaftwith centersupport.Referto
the Spicer"DriveShaftSpeedCalculatof,FormM3-11.
Fig. 6: Two-PlaneAngle DriveShaft
Page 8

UniversalJoints
The simpleuniversaljoint is basicallytwo Y-shaped
yokesconnectedby a crossmembercalleda "spider."
The spideris shaped like an "X", and has arms that ex-
tend from it called trunnions.The spider allowstwo
yoke/shaftsto operate at an angle to each other.
This type of universaljoint is designedto makedisas-
semblyand reassemblya comparativelysimplematter.
No handfitting or specialtools are required.The jour-
nals and needlebearingassembliesare the parts most
subjectto wear. When it becomesnecessaryto replace
bearings,removethe drive shaftfrom the vehicle.
The procedureused to removea drive shaft dependson w4@@11
the type and designof the universaljoints.A shaft with Fig. 7: ExplodedView of UniversalJoint
flange-typeyokes is disconnectedby removingthe at-
tachingbolts and nuts from the flangesand separating 1 Trunnion
the flangeyokesfrom the companionflanges.A shaft 2 Seal
connectedto an end yoke is disconnectedby partially 3 Bearing
disassembling the universaljoint. Universaljoints with 4 Washer
strap or cap-and-bolttype end yokes are disconnected 5 Bearing cap
by removingthe strap and bolts or caps and bolts.
After disassemblinga universaljoint, chec* the fit of
each bearingon its respectivejournal. lf loosenessis ev-
ident,the journal cross and all four bearingassemblies
and journalcross are in serviceablecondition.Clean
bearingsand reassembleuniversaljoint with bearings
and journalsin their originalpositions.
 VolvoTrucks North America,Inc. Date Group No. Page
TSI 3.2001 451 011 e(30)

Universal
Correcting Angles
JointOperating
The recommendedmethodfor correctingsevereuniver-
sal joint operatinganglesdependson the vehicle's
suspensionor drive-shaftdesign.

Typicalchart to recorddrive shafUyokean-

gles
On vehicleswith leaf-springsuspensions,axle shims
(thin wedges)can be installedbetweenthe spring and
axle housing.This will titt the axle housingto raisethe Fig. 8: TypicalAxle HousingShims
pinionup and correctthe universaljoint operatingan-
gles. Shimsare availablein a rangeof sizes to change
the pinionangle of the rear axle.
Vehicleswith tandem suspensionsuse torque or radius
rods to controlthe pinion angles.Various methodsare
used: shims betweenthe torque rod and axle; adiustable
torque rods;and eccentricbushingsin the radiusrod
leaf eye. The control of these angles can also depend on
the suspensionor vehiclemanufactureras to what
method is used. lf a fixed torque rod is used, the angle
is controlledby the use of varioussize rods.
Generally,addingor removinga 6 mm (1/4 in.) shim
from a torque rod changesthe pinion angle 314'. A 3/4"
changein the pinionanglechangesthe universalioint
operatingangle about 1/4'.
Note: Both sides of the axle must be changedto
balancethe pinion and universaljoint angles.Also, re-
memberthat changingthe pinionangle may affectthe
rear axle(s)lube level(s).
lf unusualunivercal-joint operatingangle problemsare
experienced,or for troubleshooting three or more univer-
sal joints or multipledrive-shaftarrangements,consult
your authorizedVofuoTrucksdealer.

\_
Page10

Troubleshooting
DriveShaftTroubleshooting
Fault Reason Remedy

Vibration

Lowgear shudder U-joint angle too large for continuous running Reduce U-joint continuous running angle

Worn U-joint Replace U-joint

Incompatibledrive shaft Installtwo-piece drive shaft with center support bearing

Drtve shaft weight not compatible with en- Use largerdiametertube

gine/transmission mounting

Drive shaft too long for speed Shim drive train components to equalize U-ioint angles

Unequal U-joint angles Shim drtvetrain components to equalize U-joint angles

Excessively loose U-joint for speed InspectU-iointflexeffortfor looseness,torqueto specifica-

tion, straightenand balanceshaft

Driveshaftout of balance;not straighttor- Gonsult component manuf,acturer;replace shaft bearing

sionaland/orinertialexcitation;secondary
coupleload reactionat centersupportbeadng

lmproperphasing

Inadequate torque on bearing plate capscrews Check drive shaft for conect yoke phasing. Torque bearing
capscrews to specifications

PrematureWear

Low-mileage U-joint wear End yoke cross hole misalignment Use Spiceralignmentbar to checkfor end-yokecross-hole
misalignment

Repeated U-joint wear Excessive anguladty Ch*$ U-ioint operating angles with a Spicer Anglemas-
ter Electronic Drive Shaft Inclinometer: reduce excessive
operating angles

Contamination and abrasion Lubricate to Spicer specifications. Replace U-joint kit

Endgallingof crosstrunnion ExcessiveU-boltstorqueon retainingnuts Torque bearing retention method to specifications

and bearingassembly
Contamination and abrasion Replace U-joint kit

lmproper lubrication Lubricate to Spicer specifications

VolvoTrucks North America,Inc. Date Group No. Page
TSI 3.2001 451 01 1 11(30)

Fault Reason Remedy

Needle rollers brinelled into Excessive continuous running load Reduce U-joint continuous running U-joint operating angles
bearing cup and cross trun-
nion Excessivetorque load (shock loading) angle Replace with higher capacrty U-joint assemUies

Continuous operation at high angle and or

high speed

Broken cross and bearing Worn or damaged seals Realignto properrunningangle,minimum1/2'

Causesof UniversalJointOperat-
ing AngleChanges
o Suspensionchanges,worn bushingsin the spring
hangers,worn bushingsin the torquerods,inconect
air springheight.
o Revisionsin the componentsof the drive shaft.
o Stretchingor shorteningof the chassis.
o Addingan auxiliarytransmissionor transfercase in
the main drive shaft.
o Worn engine mounts.
Page 12

Vibration-Related
Problems
Driveshaftassembliescan be the sourceof first order
vibrations(one excitationper revolution)and secondor-
der vibration(two excitationsper revolution).

First ordervibration
First ordervibrationresultsfrom an imbalancein the
drive shaft assemblycausedby improperbalancing
procedures,loss of the driveshaft balancingweights,ex-
cessiverunout,poor splinefit or undercoatingon the
drive shaft.
Drive shaftvibrationproblemsdue to an imbalanceor
first order excitationare vehicle-speedsensitivesince
drive shaft speed is directly relatedto vehicle speed by
the rear axle ratio.
In the case of conditionsas a "sloppf splinefit, imbal-
ance may be engine-torquesensitivein that the torque
causesthe splineto centeritselfditferentlythan if no
torque were present.

Second order vibration

Secondordervibrationoccurswhen the drive shaft
transmitstorquethroughan angle at each end. The exci-
tation level is relatedto both the amount of angle the
U-jointsoperatethroughand the amountof torquetrans-
mitted. A second order drive shaft excitationis sensitive
to vehiclespeed,torqueand jounce. Driveshaft angles
must be set in the optimumpositionto accommodate
variousloadsand rear-axlewindupduringacceleration.
To determineif the driveshaft is the sourceof a vibra-
tion, drivethe vehicleand note the speed rangeat which
the vibrationoccursand the vibrationfrequency(usinga
Reed tachometer).Determinethe drive shaft speedby
placingthe transmissionin directdrive and readingthe
drive shaft rpm with an engine tachometer.lf it is deter-
minedthat the vibrationis relatedto first order excitation
of the drive shaft. balancethe drive shaft.
VolvoTrucksNorth America,Inc. Date Group No. Page
TSI 3.2001 451 011 13(30)

LubricationRelatedProblems
The most commonreasonsfor U-jointwear are lack of
lubrication,inadequatelube quality,inadequateinitiallu-
bricationor failureto lubricateproperlyand often enough.
Generally,a lubricationproblemis one of two types;
brinellingor end galling.The groovesmade by the nee-
dle rollerbearingson the trunnionof the crossare known
as brinelling.Brinellingcan also be caused by too much
torque for the capacityof the U-jointused. End gallingis
a displacementof metalat the end of the trunnionand
can also be relatedto angularityproblems.Both of these
problemscan be caused by lack of lubrication.
Typical lack of Lubdcation
Failureswhichare not a resuhof lubricationfilm break-
down are associatedwith the installation,angles and
speeds,and manufacturingdiscrepancies.
Drive shaftfailuresthroughtorque,fatigueand bending
are associatedwith overload,excessivelyhigh U-ioint
angles and drive shaft lengths excessivefor operating
speeds.
The troubleshooting chart in this manual(referto "Drive
Shaft Troubleshooting" page 10) is intendedto help ser-
vice people associatecomplaintswith some of the
probablecausesand probablecorrections.Through
normalvehiclemaintenanceand recognitionof discrep-
ancies, this may enablethem to make the corrections TypicalTrunnionBrinelling
necessaryto ward off a serious breakdorun.

Typical End Galling

Page 14
4511-10-02-01
Drive ShaftoLubrication
prob-
To avoidlubrication-related
lems:
Conect Purging of U-joint
Lube all fiftings,includingthose that are often over-
looked,out of sight, dirt coveredor difficultto reach.
Note how some lube fittingsappearditferentfrom
regularchassislube fittingsand requirea needle-
nose attachmentfor the greasegun.
o Do not overlookslip-yokelubrication.
o Use conect lube technique.
a Use recommendedlubricant,such as NLGI Grade2
with extremepressureadditivesand high tempera-
ture resistance.
Lubricatenew U-jointswhen installinginto the drive-
shaft yokes.
Observerecommendedlubricationcycle. Referto
"DriveShaft, MaintenanceIntervals"page 3. One of
the most commoncauses of U-jointand slip yoke
problemsis lack of proper lubrication.Properlysized
U-jointsthat are adequately lubricatedat recom-
mendedintervalswill normallymeet or exceed
vehicleoperationrequirements.Relubrication
flushesthe joints, removingabrasivecontaminants
from the bearings.
for Universal
Lubrications Joints
For normalapplication,use a good-quality,lithium-base,
(E.P.)greasethat meets NLGI Grade
extreme-pressure
Grades3 and 4 are not recommended
2 specifications.
becauseof their greaterthickness.For severeapplica-
tions,use a good-quality,lithium-base(or equivalent)
E.P.greasewith an operatingtemperaturerangeof 157-
163"C(315-325'F). In addition,the greaseshouldmeet
the NLGIGrade 2 specifications.
Consultyour local lubricantsource for greasesthat meet
these specifications.
InitialLubrication
and RelubeCy-
cle
Replacementuniversaljoint kits containonly enough
greaseto protectneedle rollerbearingsduring storage.
It is, therefore,necessaryto completelylubricateeach
replacementkit before assemblyinto the yokes. Each
cross lube reservoirshould be fully packedwith a rec-
ommendedgreaseand each bearingassemblyshould
also be wipedwith the same grease.Fill all cavitiesbe-
tweenthe needle rollersand applya liberalgrease
coatingon the bottom of each bearingassembly.
Too much grease can cause hydraulic"lockup",making
installationdifficult.Relubethe kits after installinginto
the yokesand beforeplacinginto service.Do this
throughthe lube fitting,usingthe same grease.
Relubricationcyclesvary dependingon vehicleservice
requirementsand operatingconditions.Relubesplinesat
the intervalsrecommendedin "DriveShaft, Mainte-
nance Intervals"page 3.
Note: On-highwayis definedas all applicationsthat op-
ol the time on gravel,dirt or
erate less than 1Oo/o
unimprovedroads.lf higherthan 10% operatingtime, fol-
low otf-highwayrecommendations.
Forextendedlinehaultractors,use "10"series(1610,
and 1810)U-jointsand Glidecoteslip splines.
17'10,1760
VolvoTrucks North America,Inc.
TSI
Pre-lubing Beadng Cap
DriveShaftSupportBearingAs-
semblies
Bearingmanufacturersdo the initiallubricationand all
Spicershaft support (center)bearingsare lubedfor life.
When replacinga shaft supportbearingassembly,be
sure to fill the entire cavityaroundthe bearingwith wa-
terproof grease to shield the bearing from water and
contaminants.Put enoughgreasein to fill the cavityto
the extremeedge of the slingersunoundingthe bearing.
Lubricantsmust be waterproof.Consult your grease sup-
plierfor recommendations.
Note: Ottena speciallubricantis requiredby vehicle
specificationor customerrequest.Lubricationrecom-
mendationsin this informationare suggestedby Spicer
U-Jointengineers.Any alternatelubricants,or lubrication
procedures,are the responsibilityof the user.
Pre-lubingCenter Bearing
Date Group No. Page
3.2001 451 011 15(30)
4513-06-03-01
UniversalJoint, Checking
Beforeworkingon a vehicle,set the parkingbrakes,
placethe transmissionin neutral,and bloc* the
wheels. Failureto do so can result in unexpected
vehiclemovementand can cause seriouspersonalin-
jury or death.
Do not go underthe vehiclewhile the engine is run-
ning.Do not engageor disengagedrivenequipment
by hand from underthe vehiclewhen the engineis
running.Do not work on a shaft (with or withouta
guard)when the engineis running.Rotatingshafts
can snag clothes,skin, hair,and hands,etc. Failureto
followthese instructionscan resultin seriouspersonal
injuryor death.
The drive shaft and univercalioints generallyrequirelit-
tle maintenance.Periodicinspectionis recommended,
however,for proper drive shaft balanceand universal
joint lubrication.lf the area aroundthe caps appearsto
be excessivelydry it may indicatea need for bearing
relubricationor univercalioint replacement.A failinguni-
"clunks"with
versaljoint often squeakson start-upor
directionchange.
To keepa vehicleoperatingsmoothlyand economically,
carefullyinspectthe drive shaft at regularintervals.Vi-
brationsand problemswith the U-iointand shaft support
(center)bearingare causedby such things as loose end
yokes,excessiveradial (side-to-sideor up-and-down)
Page 16

looseness,slip spline radiallooseness,bent shafttubing

or missingplugsin the slip yoke.
1

w4000015

Checking Cap for Looseness

Checkfor excessiveloosenessacross 0.152mm

of lnputandOuputYokes
Inspection the ends of the bearingassemblies (0.006in.)
Checkthe output and input end yokes and trunnions.This loosenessshould
on both the transmissionand rear not exceed0.152mm (0.006in.) maxi-
axle(s)for looseness.lf loose,discon- mum.
nect the drive shaft and retorquethe
retainingnut to specification.lf a yoke 4
replacementis required,alwaysinstall
a new retainingnut when replacingthe
yoke.Also, if the retainingnut is dam-
aged, it must be replaced.Most
self-lockingretainingnuts are only
used once.

w4000016

Checking Slipshaft Splines for Looseness

Checkthe slip splinefor excessivera- 0.178mm

dial movement.Radiallooseness (0.007in.)
betweenthe slip yoke and the tube
shaft should not exceed0.178 mm
Checking End Yokes for Looseness (0.007in.).

lf the end yokes are tight, checkfor 0.025mm

excessiveradial loosenessat the (0.001in.) 5
transmissionoutput and rear axle in- 0.076-0.178mm Place an axle stand next to the drive
put shaftsat their respectivebearings. (0.003-0.007in.) shaft at the slip yoke. Positiona dial
Transmissionoutputshaft radialplay 0.33-{.43 mm indicatorwith a magneticbase onto
shouldnot exceed0.025 mm (0.001 (0.013-0.017in.) the axle stand. Set the dial indicatorto
in.) zero against the yoke and read off the
Rear axle input shatt radialplay movement.
shouldnot exceed0.076- 0.178mm
(0.003- 0.007in.) for a new axleand
0.33- 0.43mm (0.013-0.017 in.)for a
rebuiltaxle using reusedparts.
Volvo Trucks North America,Inc. Date Group No. Page
TSI 3.2001 451 011 17(30)

8
Placean axle stand nextto the drive 150 g (5 oz)
shaft and positiona dial indicatorwith
a magneticbase onto the axle stand.
Set the dial indicatorprobe up against
the drive shaft and set it at zero. Ro-
tate the drive shaft and read the
runout.The best way to checkthe
drive shaft balanceis to set a dial indi-
cator and take the highestreading,
place a weighton the low side, then
spin the driveshaft and checkfor bal-
ance. Do not use more than 150 g (5
oz).
Checking Drive Shaft for Damage
9
Checkthe shaftfor damage,bent tub-
ing or missingbalanceweights.Make
sure there is no buildupof foreignma-
terial, such as undercoator concrete
on the shaft. lf found,it shouldbe re-
moved.

:c)

Ghecking Slipshaft End Plug

Check to see that the end plug is not

loose or missing.lf it is, have it re-
Checking Drive Shaft for Runout
paired or replaced.Loose or missing
lf a runoutreadingis required,take 0.64 mm plugs indicatethat there is not enough
the readingwith the drive shaft in the (0.025in.) slip movementin the drive shaft.
vehicle,the rear axle jacked up, and
Closedlengthof the drive shaft may
the transmissionin neutral.This allows
be too great, requiringa change in the
drive-shaftrotationby hand to check
drive shaft length.Continueduse of a
the dial indicatorreading.The runout
long drive shaft can lead to failures of
readingshouldbe taken at variouslo-
the transmissionor rear axle bearing,
cationsand shouldnot exceeda
as well as otherjournalsand bearings.
maximumof 0.64 mm (0.025in.).
Page18

4511-01-01-01
Drive Shaft, Removal

Beforeworkingon a vehicle,set the parkingbrakes,

placethe transmissionin neutral,and blockthe
wheels.Failureto do so can resultin unexpected
vehiclemovementand can cause seriouspersonalin-
jury or death.

Do not go under the vehiclewhile the engineis run-

ning.Do not engageor disengagedrivenequipment
by handfrom underthe vehiclewhen the engineis
running.Do not work on a shaft (with or withouta Fig. 10: RemovingTabsfrom Bolts
guard)when the engineis running.Rotatingshafts
Bend loc*-straptabs away from bolt
can snag clothes,skin, hair,and hands,etc. Failureto
headswith a chisel.
followthese instructionscan result in seriouspersonal
injuryor death.
2
:::::::i:ili::ii:i:ii:tliiriritri:iii:::i:il::

iuili:ffi
t" #ilili:iil+iillll,lri:iril:ri;riXri:riirn:ir:,ii
'i,:?;l;l+lif:.I;:rdi,ii:ll
!;,i!1,:l!f;i::l',i ii::i: iili::li"r:i:li ::lli

Driveshafts can be very heaqy.Install a support strap

whenservicinga driveshaft. Failureto insall a sup-
port strap can result in personalinjury.

Removal(full round end yoke-style)

Note: Beforeremovingthe drive shaft, mark the slip yoke
assemblyand tube shaftwith a markingstick or paint to
ensureproperalignmentwhen reassembled.This is
knownas keepingthe drive shaft yokes"in phase".

Fig. 11: RemovingBearingGap Bolts

Removebolts (four)from each bearing
assemblyconnectedto the transmis-
sion and axle end yoke.
Fig. 9: AlignmentMarkingson DriveShaft

AcAunoN
Neverheat componentswhen disassembling.

Note: Use the drive shaft removalmethod that ensures

safety and ease of removalwithout damagingthe drive
shaft,transmissionor axle components.Volvosuggests
usinga hydraulicjack, nylonstrapand the two-jawpuller.
VolvoTrucks North America,Inc. Date Group No. Page

TSI 3.2001 451 011 1e(30)

Removal(half-roundend yokestyle)
For half-roundend yokedisassembly,installa nylon
supportstrap.Removethe strap retainingboltsone end
at a time and releasethe drive shaft.

Removal(flange-yokestyle)
1
Install nylon support strap. Loosenand
remove nuts and bolts securingflange
yoke to transmissionor axle compan-
ion flange.

2
Holdingdrive shaft firmly,tap loose
and compressfrom one end and lower
Fig. 12: TappingOut BearingCaP to floor
Releasebearingassembliesfrom the
yoke cross holes by lightly tapping on 3
the yoke,which causesthe bearing Repeatat other end.
cap to come out.

4 4513-03-04-01
UniversalJoint, Replacement

Drivelinecomponentsshouldbe assembledaccording
to proper procedures.Do not use worn out or dam-
aged drivelinecomponents.Do not use driveline
@mponentsin a non-approved application.Failureto
followthese instructionscan resuhin seriouspersonal
injuryor death.

Fig. 13: RemovingTrunnionfrom the End Yoke

Freethe trunnionfrom the end yoke
by tiltingthe trunnionand collapsing
the drive shaft.
lf only one end of the drive shaft re-
quiresservice,disconnectthat end,
unscrewthe slip seal (dustcap)from
the slip yoke assembly,and then pull
apart or slide off the assembly.When
removingthe entiredrive shaft,disas-
sembleone end at a time and
carefullylay the disconnectedend on
the floor.When reassembling,BE
SUREthat the arrowsor markson the
shaft and slip joint are in line to keep
the drive shaft yokes in phase.
Page 20
Disassembly
1
Fig. 14: RemovingCap LockingTabs
Placethe drive shaft in a benchvise,
clampingon the tube adjacentto the
cross and bearingassembliesbeing
removed.
AcAunoN
Do not distort the tube with excessivepressure.
:
Fig. 15: RemovingCross
Completelyremove the cross and
bearingsfrom both ends of the drive
shaft by disassemblingthe bearingas-
sembliesfrom the slip yoke and tube
yoke (and flange yoke where applica-
ble).
Fig. 16: CheckingYokeAlignment
After removingthe cross and bearings
at both ends, inspectthe cross hole
surfacesfor damage or raisedmetal.
Raisedmetal can be removedwith a
rat-tailor half-roundfile and emery
cloth.
4
Gheckthe yoke lug cross holes with a
No-GoWear Gauge and then use a
SpicerAlignmentBar to inspectfor
damageby slidingthroughboth cross
holessimultaneously. The alignment
bar identifiesyoke lugs that have
taken a set because of excessive
torque.Raisedmetal or distortedlugs
can cause prematurecross and bear-
ing problems.
5
At this time, clean the cross holesof
the yokeson the transmissionand
axle and inspectwith an alignmentbar
gaugeas describedin step 4.
lf, after properlycleaningthe cross
holes,the alignmentbar will not pass
throughsimultaneously, the yoke lugs
are distortedand the yoke or yokes
mustbe replaced.
 Volvo Trucks North America,Inc. Date Group No. Page
TSI 3.2001 451 011 21(30)

Assembly(full and half-rounddrive

shafts)
Placeeach end of the drive shaft, less crossand bearing
kits, into a benchvice. Checkthe paint markingsplaced
on the tube and slip yoke assemblybeforeremoving
from the vehicleto be sure they are linedup or in phase.

Fig. 17: DriveShaft Phasing

Conect phasing
1
2 Inconect phasing F@z
Bearingc.p J'ffinnion
Fig.19: Reinstalling
Apply an anti-seizecompoundto the
outsidediameterof the four bearing
assemblies.Moveone end of the cross
to cause a trunnionto proiectthrough
the cross hole beyondthe outer ma-
chinedface of the yoke lug. Placea
\ bearingassemblyover the trunniondi-
ameterand align it to the cross hole.
Holdingthe trunnionin alignmentwith
the cross hole, press bearingflush to
face of end yoke by hand.
Note: Make sure to pre-lubethe bear-
ing cap beforeinstalling.

K
Fig. 18: Reinstallingthe Grossinto the End Yoke
3
When the bearingassemblyis com-
pletelyseated, put the lock plate tab in
Removethe cross and bearingsfrom
place. Insertthe 'Grade 8" capscrews
the box and removeall four bearing
that are furnishedwith the kit through
assemblies.Rotatethe cross to in-
the capscrewholes in both the lock
spect for presenceof the one-way
strap and bearing assembly.Thread
check valve in each lube hole of all
four trunnions.Then positionthe cross with hand or wrench into tapped holes
in yoke. Do not torque down bolts.
into the end yoke with its lube fittingin
line as near as possiblewith the slip
spline lube fitting.Keepthe lube fitting
on the inboardside.
Note: The zerk fittingmust be on the
compressionside when drivingfor-
ward.
Page ?2
Fig. 20: Tappingin BearingCap
lf bearingassemblybindsin cross
hole,tap with ball peen hammerdi-
rectlyin centerof bearingassembly
plate. Do not tap outer edgesof bear-
ing plate.
Note: Exactfit of all drive shaft com-
ponentsis extremelyimportant.The
correctparts and clean matingsur-
faces are essentialfor safe operation
and good repair.
5
Move the cross laterallyto the oppo-
site side and throughthe cross hole
beyondthe machinedsurfaceof the
yoke lug. Placea bearingassembly
over the crosstrunnionand slide it into
the cross hole, seatingthe plateto the
face of the lug.
Note: Projectingthe trunnionthrough
a cross hole beyondthe machinedsur-
face of the lug will providea surfaceto
help alignthe bearingassemblywith
the crosshole. Followthis method
also whenassemblingfull rounddrive
shaftsto full round yokesof vehicleat
transmissionand axle or axles.
Fig.21: Reinstalling
BearingCap Bolts
Put the lock plate tab in place and
thread the bolts with hand or wrench
into tapped holes in yoke.
7
Repeat installationprocessfor cross
and bearing kit at the oppositeend of
the drive shaft. Make sure to position
the cross in the yoke so that the lube
fitting is in line with the lube fittingat
the other end.
8
For flangeyoke applications,installthe
flange yoke,bearingassembliesand
bolts at this time.
A cAUnoN
Usinga new cross with a worn bearingassembly,or a
worn cross with a new bearingassemblywill cause
rapid wear, makinganotherreplacementnecessaryin
a short time. Alwaysreplacethe cross,four bearing
assembliesand bolts as a unit. Full roundand half
round requiredifferentkits.
VolvoTrucksNorth America,Inc. Date Group No. Page
TSI 3.2@1 451 011 23(30)

4511-02-01-01 Installation
DriveShaft,Installation

Beforeworkingon a vehicle,set the parking brakes,

place the transmissionin neutral,and block the
wheels. Failureto do so can result in unexpected
vehiclemovementand can cause seriousperconalin-
jury or death.
"00" SERIES

rONE-WAY CHECK VALVE

Do not go underthe vehiclewhile the engineis run-

ning. Do not engageor disengagedrivenequipment
by handfrom underthe vehiclewhen the engineis
running.Do not work on a shaft (with or without a
guard)when the engineis running.Rotatingshafts
can snag clothes,skin, hair,and hands,etc. Failureto
follow these instructionscan result in serious personal
injuryor death.
DOI.'BLE LIP SEAL
"10" SERIES

Fig.22:Journal Cross and BearingAssemtifl*

Drivelinecomponentsshouldbe assembledaccording
to proper procedures.Do not use worn out or dam-
aged drivelinecomponents.Do not use driveline
componentsin a non-approvedapplication.Failureto
follow these instructionscan resuft in serious personal
injuryor death.
Drive shafts can be very heavy.Install a support strap
when servicinga drive shaft. Failureto installa sup-
port strap can result in personaliniury.
The installationof a drive shaft does not present any un-
usual mechanicaldifficulties.Beforeinstallation,check
the drive shaft for the followingitems:
o Damageor dents on the drive shafttubing.
o Splinesshouldslidefreely with slightdrag from slip
shaft seal.
Cross shouldflex and be free from excessivebind. A
slight drag is the most desirableconditionon a new
cross and bearing kit. Excessiveloosenessis unde-
sirable and will result in an unbalanceddrive shaft.
Mountingflangesand pilotsshouldbe free from
buns, paintand foreignsubstanceswhich would not
allow proper seatingat assembly.
Page 24
Full roundend-yokestyle
Fig.23: PlacingEnd Yokein a HorizontalPosition
Rotatethe transmissionend yoke by
puttingthe transmissionin neutraland
the axle end yoke by jac*ing up one
rear wheel, so the cross holes are in a
horizontalposition.
2 Placea bearing assemblyover the
Fig. 24:InstallingTrunnionindH'i
Tilt the crosstrunnionsof the drive
shaft (bothends) with trunnionspoint-
ing toward each other from end to
end, one side. Installwith the slip joint
nearestthe source of power. Use a
nylonsupportstrap to aid in handling
the drive shaft.
3
Holdingthe drive shaft firmly,proiecta
trunnionin an outwardpositionbe-
tweenthe lugs of eitherthe axle or the
transmissionend yoke and througha
cross hole. Repeat at oppositeend.
The drive shaft is being supportedat
each end by one trunnionsurfacein a
cross hold and the nylon supportstrap.
Tilt a crosstrunnion untilthe opposite
side can be inserted througha cross
hole.Repeatat oppositeend. The
drive shaft is now being supportedat
each end by two trunnionsurfacesin
the cross holes and the nylon support
strap.
w40@o35 4
Applyan anti-seizecompoundto the
outsidediameterof the remainingfour
bearingassemblies.Moveone end of
the shaft to cause a trunnionto project
throughthe cross hole beyondthe
outer machinedface of the yoke lug.
5
trunniondiameterand align it to the
cross hole.Holdingthe trunnionin
alignmentwith the cross hole,press
bearingassemblyflush to face of end
yoke by hand. lf bearing assembly
binds in cross hole, tap with ball peen
hammerdirectlyin centerof bearing
assemblyplate. Do not tap outer
edgesof bearingplate.
Yokes
VolvoTrucks North America,Inc.
TSI
Fig. 25: ReinstallingBearingCap Bohs
Slide the shaft to project an opposite
trunnionthroughthe cross hole be-
yond the face of the end yoke. Again,
place a bearing assemblyover the
trunnion,align and place hands on op-
posite bearing assembly,and press
both inwardflush to yoke faces. lf as-
semblybinds,tap with ball peen
hammeras outlinedin step 5. Put the
lock plate tab in place and insert the
"Grade 8" capscrewsthroughthe holes
in the loc-kplates and bearing assem-
blies. Thread capscrewsinto end
yokes. Tighten with wrench until plates
are flush against end yoke faces.
7 For half-roundyokes, place the bearingassemblieson
Lubricatethe cross and bearing as-
sembly until lube appearsat all four
seals. Also chec* slip yoke lubrication.
Date Group No. Page
3.2001 451 011 25(30)
Fig. 26: BendingLockTabsOver
Torqueall eight bolts to specification.
Refer to "Full Round End Yoke"page
3. Bend lock plate tabs to flat of cap-
screw heads to lock in place.
Half-roundend yoke style
AcAUnoN
Do not reuse half-round,self-lockingretainingbolts
more than five times. Follourinstructionsexplicitlyto
preventdanger of serious perconalinjury or death
from loss of drive shaft function. lf in doubt as to how
many times bolts have been removed,replacewith
new bolts.
the cross trunnion and seat the bearingcup into the end
yoke shoulders.Place straps over the bearing assem-
blies, thread special self-lockingcapscrewsinto tapped
holes and torque bolts to specification.Referto
"Half-RoundEnd Yoke"page 3. Lubricatethe cross and
bearingassemblies.
Note: Bearingcaps shouldbe held in place by clips or
tape so they will not fall otf when installingthe drive shaft.
Page 26

Flangeyoke style
With nylonsupportstrap in place and holdingthe drive
shaft firmly,align the (permanentend) flange pilotsof
the driveshaft flangeand axle companionflangewith
each other.Align bolt holesand installbolts,lock wash-
ers and nuts to temporarilysecure drive shaft to axle.
Gompressthe slip assemblyto positionthe oppositeend
of the driveshaft to the transmissioncompanionflange.
Align bolt holesand installbolts, lock washers,and nuts
and torqueto specifications.
Note: Wheninstallingnew bearingassembliesinto cross
holes,the lockingflat on the bearingassemblymust be
alignedwith the lockingflat in the yoke cross hole.
Proper locationof lockingflats will preventthe bearing
assemblyfrom rotating.

4513-10-02-01 Fig. 27: GreasingU-joint

UniversalJoint, Lubrication
Beforeworkingon a vehicle,set the parking brakes,
placethe transmissionin neutral,and bloc* the
wheels.Failureto do so can result in unexpected
vehiclemovementand can cause seriouspersonalin-
jury or death.
Use the properlubricantto purge all
four sealsof each U-joint.This flushes
abrasivecontamanantsfrom each
bearingassemblyand ensuresall four
are filled.Pop the seals.
2
lf any seals fail to purge,movethe
drive shaft from side to side and then
apply gun pressure.This allows
greaterclearanceon the thrust end of
the bearingassemblythat is not purg-
ing.

Do not go underthe vehiclewhile the engineis run- 3

ning. Do not engageor disengagedriven equipment
by handfrom underthe vehiclewhen the engineis
running.Do not work on a shaft (with or withouta
guard)whenthe engineis running.Rotatingshafts
can snag clothes,skin, hair,and hands,etc. Failureto
followthese instructionscan resultin seriouspersonal
injuryor death.
Becauseof the superior sealing capa-
bilityof the seal designon the 1610,
1710,1760,1810and 1880Series,
there will occasionallybe one or more
bearingassemblyseals that will not
purge.
Volvo Trucks North America,Inc. Date Group No. Page
TSI 3.2001 451 01 1 27(3ol

Slip Splines
The lubricantused for U-jointsis satisfactoryfor slip
splines.Glidecoteand steel splinesboth use a good E.R
greasemeetingNLGI Grade2 specifications.
Relubesplinesat the intervalsrecommendedin "Drive
Shaft, MaintenanceIntervals"page 3.

Fig. 28: LooseningBearingCap

Ilelease seal tension by loosening the
bolts holdingthe bearingassembly
that does not purge. lt may be neces-
sary to loosenthe bearing assembly
approximately 0.625mm (1/16in.)
minimum.lf looseningit does not
cause purging,removethe bearing
assemblyto determinecause of block-
age.

5
Retorquebotts to specification.

Fig. 29: LubricationSlip Shaft

Apply grease gun pressureto the lube
fitting until lubricantappears at the
pressure-reliefhole in the plug at the
slip yoke end of the spline.
Page 28

the Vehicle
Preparing
1
Inflatethe tires to normaloperating
pressure.

Fig. 30: TypicalSlip ShaftSpline Galling
Now coverthe pressure-reliefhole
with your finger and continueto apply
pressureuntil grease appearsat the
slip yoke seal.
2
Parkthe vehicleon a flat and level
surface,front to rear and side to side.
Do not level the vehicle by jacking up
the front or rear axles. Do not apply
the parking brakes,and make sure the
rear air-suspensionride heightis cor-
rect, if applicable.
3
Jack up one rear wheel,just enough
to clear the floor.

AcAunoN Procedure
In cold temperatures,be sure to drive the vehicleim-
mediatelyafter lubricating.This activatesthe slip 1
spline and removesthe excessivelubricant. Failureto
do so can cause the excesslubricant to stilten in the
cold weatherand force the plug out. The end of the
splinewouldthen be opento collectcontaminants
and cause the spline to wear and/or seize.

4511-06-02-01
- \ =\rl-
Drive Shaft Angles, Checking

Beforeworking on a vehicle,set the parking brakes,

placethe transmissionin neutral,and blockthe
wheels.Failureto do so can result in unexpected YokeAngle
Fig. 31: CheckingTransmission
vehiclemovementand can causeserious personalin-
jury or death. Rotatethe rear wheel by hand until
the output yoke on the transmissionis
vertical,then lower the rear wheel to
the floor. Check the drive shaft angles
in the same loaded or unloadedcondi-
tions as when the vibrationor noise
occurred.
Do not go under the vehiclewhilethe engine is run-
ning.Do not engageor disengagedriven equipment
by handfrom underthe vehiclewhen the engineis
running.Do not work on a shaft (with or withouta
guard)when the engineis running.Rotatingshafts
can snag clothes,skin, hair,and hands,etc. Failureto
followthese instructionscan result in serious personal
injuryor death.
VolvoTrucks North America,Inc.
TSI
Fig. 32: CheckingDrive-ShaftAngle
'lic
determinedrive shaft angles,an
electronicprotractor,or equivalent,is
required.To use the electronicprotrac-
tor, place it onto the componentto be
measured.A displaymodulewill show
the angle and in which directionit
slopes.
3 5
Always measurethe slope of the driv-
etrain going from front to rear. A
componentslopes downwardif the
rear is lowerthan the front. A compo-
nent slopesupwardwhen it is higher
at the rear than at the front.
Note: Two outlets for the electronic
protractorare Spicer and SchaeviE
Sensing Systems.Contactyour local
Spicerdistributorfor the Spicer model.
For the SchaeviE model contact
Schaevitzat 1-800-545-3243.
Date Group No. Page
s.2oo1 451 01 1 2e(30)
>4-_:
Fig. 33: CheckingFront-AxleYokeAngle
Check and recordthe angle on the
main transmission.This readingcan
be taken on the end yoke lug with the
bearing cap assemblyremoved;or on
a flat, machinedsurfaceon the trans-
missionparallelor perpendicularto
the output-shattyoke lug plane.
Recordthe reading.
Chec* the drive shaft angle between
the transmissionand the bnarardrear
axle. On short tube lengrthdrive shafts,
check the angle of the drive shatt on
eitherthe tube or slip-tubeyoke lug
with the bearing cap assemblyre-
moved.On long tube lengilhdrive
shatts, check the angle on the tube at
least 76 mm (3 in.) away from the cir-
cle tube weld or at least25 mm (1 in.)
from a balanceweight. Be sure to
removeany rust, scale or sound-
deadeningcompoundsfrom the tube
shaft to obtain an accuratemeasure-
ment.
6
Checkthe forward rear axle input yoke
angle.This can be done by removing
a bearingcap assemblyand measur-
ing the angleon the yoke lug, or
measuringat a flat, machinedsurface
on the rear axle parallelor perpendic-
ular to the input-shaftyoke lug plane.
7
lf applicable,measurethe output-yoke
angle of the forward rear axle through
the shaft yoke.This is the angle of the
inter-axledrive shaft betweenthe tan-
dem axles and the input yoke angle of
the rear-rearaxle.
Page 30

8
To determinethe univercaljoint oper-
ating angles,simplyfind the ditference
in the slopesof the components.

9
When the slopesare in the same di-
rectionon two connectedcomponents,
subtractthe smallerreadingfrom the
highestreadingto find the universal
joint operatingangle.When the slopes
are in the opposite directionon two
connectedcomponents,add the
readingsto find the universaljoint op-
eratingangle.

10
Comparethe universaljoint operating
anglesto the instructionsin "Maximum
Drive ShaftOperatingAngle"page 3.