zj driveshaft

7/28/2019 ZJ Driveshaft

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PROPELLER SHAFTS

CONTENTS

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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1PROPELLER SHAFT REPLACEM ENT . . . . . . . . . 7SERVICE DIAGNOSIS/PROCEDURES . . . . . . . . . 3

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 14UNIVERSAL JOINT REPLACEM ENT . . . . . . . . . . 9

GENERAL INFORMATION

PROPELLER SHAFTSTh e f u n ct ion of a p r op sh a f t is t o t r a n sm it p ow e r

f r om on e p oin t t o a n ot h e r in a sm oot h a ct ion . Th e

s h a f t i s d e s ig n ed t o s e n d t or q u e t h r ou g h a n a n g l ef r om t h e t r a n s m i ss ion (t r a n s f er ca s e on 4WD v e-

hicles) to the axle (Fig. 1).

Th e p rop el le r s h a f t m u s t op er a t e t h r ou g h con -

s t a n t l y c h a n g i n g r e l a t i v e a n g l e s b e t w e e n t h e t r a n s -

mission and axle. I t must also be capable of changing

length while transmitt ing torque. The axle rides sus-

p en d e d by sp r in g s in a f loa t in g m o t ion . Th is m e a n s

t h e p rop el le r s h a f t m u s t b e a b le t o ch a n g e a n g les

when going over various roads. This is accomplished

through un iversal joints, which permit the propeller

sha ft to opera te a t different an gles. The slip joints (or

yokes) permit contraction or expansion.

Tubular propeller sha fts a re bala nced by t he ma nu-

facturer with weights spot welded to the tube.

T h e p r o p e lle r sh a f t is d e sig n e d a n d bu il t w it h t h e

y ok e l u g s i n l in e w i t h e a ch ot h e r w h i ch i s c a l le d

phasing. This design produces the smoothest running

condition. An out of pha se sha ft can cause a vibration.

Before undercoating a vehicle, the propellershaft and the U-joints should be covered. Thiswill prevent the undercoating from causing an

unbalanced condition and vibration.

CAUTION: Use exact replacement hardware for at-taching the propeller shafts. This will ensure safeoperation. The specified torque must always be ap-plied when tightening the fasteners.

UNIVERSAL JOINTSThe front and rear prop shafts use the 1310 series

universal joint .

Two different t ypes of U-joints syst ems a re used:

Single cardan U-joint (Fig. 2)

Double cardan U-joint (Fig. 3)

LUBRICATIONThe slip yoke on the front shaft is equipped with a

z er k t y p e l ub r ica t i on f it t i n g. U s e a m u lt i -p ur pos e

N L G I G r a d e 2 EP lu br ica n t , r e f e r t o G r o u p 0, L u br i-

ca t ion a n d Ma in t e n a n ce f or a d d it ion a l in for m a t ion .

Th e f a ct or y in st a l led U -join t s a r e lu br ica t e d f or t h e

Fig. 1 Front & Rear Propeller Shafts (4WD)

Z PROPELLER SHAFTS 16 - 1


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life of the vehicle and do not need re-lubrication. All

U-joints should be inspected for leakage and damage

e a ch t im e t h e ve h icle is se r vice d . I f se a l le a k a g e o r

dam age exists, the U-joint should be replaced.

Fig. 2 Single Cardan U-Joint (Typical)

Fig. 3 Double Cardan (CV) U-Joint

16 - 2 PROPELLER SHAFTS Z


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SERVICE DIAGNOSIS/PROCEDURES

INDEX

page page

Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Universal Joint Angle Measurement . . . . . . . . . . . . 4Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

VIBRATIONTires that are out-of-round or wheels that are unbalanced

wil l cause a low frequency vibrat ion. Refer to Group 22,

Tires And Wheels for additional information.

B r a k e d ru ms t h a t a r e u nb a la n ced w i ll ca u se a

h a r s h , l ow f r eq u en cy v ib r a t i on . R ef er t o G r o up 5,

Brakes for addit ional information.

D r ivelin e vibr a t io n ca n a lso r e su lt f r om loose or

d a m a g ed e n gin e m o u n t s. Re fe r t o G r ou p 21, Tr a n s-

missions for a ddit ional information.

P ropeller sha ft vibra tion will increase a s t he vehiclesp e e d is in cr e a se d . A vibr a t io n t h a t o ccu r s w it h in a

specific speed ran ge is not caused by propeller shaft

unbalance. Defective universal joints or an incorrect

propeller shaft angle are usually the cause.

UNBALANCEIf propeller shaft unbalance is suspected, it can be

verified with the following procedure.

Removing and re-indexing the propeller shaft

180 may eliminate some vibrations.

Clean al l the foreign material from the propel ler shaft

an d t he universal joints (mud, un dercoat ing, etc.).

I n s pe ct t h e p rop el le r s h a f t f or m i ss i ng b a l a n ce

weights, broken welds, and bent areas.If the propel-

ler shaft is bent, it must be replaced.

Ensure the universal joints are not worn, are properly

instal led, and are correct ly a l igned wi th the sha ft .

Check the universal joint clam p screws t orque.

(1) Raise the vehicle.

(2) Re m o ve t h e w h e e l a n d t ir e s. I n st a l l t h e w h e e l

lu g n u t s t o r e t a in t h e br a k e d r u m s.

(3) Ma r k a n d n um ber t h e pr op s ha f t t ub e s ix

inches from the yoke end at four posit ions 90 apa rt .(4) Ru n a n d a cce le r a t e t h e ve h icle u n t i l vibr a t io n

occu r s. N o t e t h e in t e n sit y a n d sp ee d t h e vibr a t io n

occurred. Stop the engine.

(5) I n st a l l a scr ew cla m p a t Position 1 (Fig. 1).(6) S t a r t t h e e n gin e a n d r e -ch eck f or vibr a t io n . I f

t h er e i s l it t l e o r n o c h a n g e i n v ib r a t i on , m ov e t h e

clamp to one of the other three posit ions. Repeat the

vibration test .

(7) If there is no change in vibration, the vibration

may not be caused by prop shaft unbalance.

(8) I f t h e v ib r a t i on d ecr ea s e d, i n st a l l a s econ d

clam p (Fig. 2). Repeat the vibra tion test .(9) I f t h e cl a m ps ca u s e a n a d d i t ion a l u n ba l a n c ed

DRIVELINE VIBRATION



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condition. Separa te the clam p screws (1/4 inch abovea n d 1/4 in ch below t h e m a r k ). Re pe a t t h e vibr a t io n

test (Fig. 3).

(10) I n cr ea se d ist a n ce be t w e en t h e cla m p scr e w s

a n d r e pe a t t h e t e st u n t i l t h e a m ou n t o f vibr a t io n is a t

t h e lo w est level . B e n d t h e sla ck e n d o f t h e cla m p s so

the screws will not loosen.

(11) Inst all t he wh eel a nd t ires. Lower t he vehicle.

(12) I f t h e a m o u n t of vibr a t ion r e m a in s u n a cce pt -

able, apply procedures at the front end of the propel-

ler sh a f t .

RUNOUT(1) Remove dirt , rust , paint , and undercoating from

the propeller sha ft sur face. Areas where th e dial indi-cator will contact the shaft must be clean.

(2) The dial indicator must be installed perpendicu-

la r t o t h e sh a f t su r f a ce .

(3) M e a s ur e r u n ou t a t t h e c en t er a n d e nd s a w a y

from welds.

(4) Refer to Runout Specificat ions chart .

(5) Rep la ce t h e p r op eller sh a f t i f t h e r u n ou t e x-

ceeds th e limit .

UNIVERSAL JOINT ANGLE MEASUREMENT

INFORMATION

Wh e n t w o sh a f t s in t er sect a t a com m o n u n iver sa ljoi n t , t h e a n g l e i s ca l l ed t h e op er a t i n g a n g l e. Th e

la r g e r t h e o p e r a t in g a n g le , t h e la r g e r t h e a m o u n t o f

acceleration a nd decelerat ion of the joint . For every

r e vo lu t io n t h e r e a r e t w o a cce le r a t io n s a n d d e ce le r a -

t i on of t h e u n iv er s a l joi n t . Th i s s pe ed in g u p a n d

slow in g d ow n of t h e join t m u st be ca n celled t o p r o -

duce a smooth power flow. This is done through phas-

ing a nd proper universal joint w orking a ngles.

A propeller shaft is properly phased when the yoke

ends are on the same plane or in line. A twisted shaft

will throw the yokes out of phase and cause a notice-

able vibration.When ta king universal joint angle mea surements or

checking pha sing w ith tw o piece shafts, consider each

sh a f t se pa r a t e ly. O n 4WD veh icles, t h e f r on t sh a f t

input (pinion shaft) angle has priority over the caster

angle.

Ideally the driveline system should have:

Angles that are equal or opposite within 1

degree of each other

Have a 3 degree maximum operating angle

Fig. 1 Clamp Screw At Position 1

Fig. 2 Two Clamp Screws At The Same Position

Fig. 3 Clamp Screws Separated

RUNOUT SPECIFICATIONS



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Have at least a 1/2 degree continuous operat-ing (propeller shaft) angle

En g in e sp e e d (R.P.M.) is t h e m a in f a ct o r in d e t e r -

m in in g m a x im u m a llow a ble op er a t in g a n g le s. As a

g u id e t o m a x im u m n o r m a l o p e r a t in g a n g le s r e f e r t o

the chart listed (Fig. 4).

INSPECTION

Before measuring universal joint angles, thefollowing must be done. Inflat e a ll t ires t o correct pressure.

Check angles in the same loaded or unloadedcondition as when the vibration occurred. Propshaft angles will change according to theamount of load in the vehicle. Always checkangles in loaded and unloaded conditions. Check the condition of all suspension springs and

verify a ll fast eners ar e torqued to specifications.

Check the condition of the engine and tra nsmission

mounts. Verify all fasteners are torqued to specifica-

tions.

MEASUREMENT

To a ccurat ely check d riveline a lignment, ra ise a nd

su pp or t t h e ve hicle a t t h e a x les a s level a s p ossible.

Allow the wheels and propeller shaft to turn. Remove

snap rings from universal joint so Inclinometer 7663

(J -23498A) base sits flat on cap.

(1) R ot a t e t h e s h a f t u n t il t r a n s m i ss ion /t r a n s f er

case output yoke bearing is facing downward.Always make measurements from front to

rear.(2) Place Inclinometer on yoke bearing (A) parallel

to the shaft (Fig. 5). Center bubble in sight glass andrecord m easurement.

This mea surement w ill give you t he tra nsmission orOUTP U T YOKE ANG LE (A).

(3) Rotate propeller shaft 90 degrees and place In-

clinometer on yoke bearing parallel to the shaft (Fig.6). Center bubble in sight glass and record measure-

m e n t .T h is m e a su r e m e n t w il l g ive y o u t h e PRO PEL L ER

SHAFTANGLE (C).(4) Subtract smaller figure from larger (C minus A)

t o ob ta i n t r a ns mis sion OU TP U T OP E R ATI NG

AN G L E.

(5) Rotate propeller shaft 90 degrees and place In-

cl in om et e r on p in i on y ok e b ea r i n g p a r a l lel t o t h e

shaft (Fig. 7). Center bubble in sight glass and record

measurement.

This measurement will give you the pinion shaft or

INPUT YOKE ANGLE (B).

(6) Subtract smaller figure from larger (C minus B)

to obtain axle INPUT OPERATING ANGLE.

Refer to rules given below and the example in (Fig.

8) for addit iona l informat ion.

G o od ca n c el la t i on of u -joi n t op er a t i n g a n g l es

(within 1)

Operating angles less than 3

At least 1/2 of one degree continuous operating(propeller shaft) angle

Fig. 4 Maximum Angles and R.P.M.

Fig. 5 Front (Output) Angle Measurement (A)

Fig. 6 Propeller Shaft Angle Measurement (C)



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ADJUSTMENT WITH CAMS

Ad ju s t t h e a n g l e b y r ot a t i n g ca m s on t h e u pp er

suspension arms (Fig. 9). On 4WD vehicles, the front

sh a f t in pu t (p in ion sh a f t ) a n g le h a s p r ior i t y over t h e

caster angle.

A ca m s er v ice k it i s a v a i l a b le t o a d ju s t t h e r ea r

propeller shaft angle. The cam kit is installed in the

upper suspension arms at the axle.

Fig. 7 Rear (Input) Angle Measurement (B)

Fig. 8 Universal Joint Angle Example

Fig. 9 Angle Adjustment With Cams



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PROPELLER SHAFT REPLACEMENT

PRECAUTIONSU se e x a ct r e p la ce m e n t h a r d w a r e f o r a t t a ch in g t h e

propeller sha fts. This will ensure sa fe opera tion. The

sp e cif ie d t o r q u e m u st a lw a y s be a p p lie d w h e n t ig h t -

ening the fasteners.

It is important to mark the propeller shaft yoke anda x le or t r a n sm ission y ok e bef or e r e m ova l (F ig . 1).

Th is w il l a ssu r e cor r e ct p h a sin g a n d e lim in a t e p os-

sible vibrat ion.

CAUTION: Do not allow the propeller shaft to drop

or hang from either universal joint during removal.

Attach it to the vehicle underside with wire to pre-

vent damage to the universal joints.

CAUTION: It is very important to protect the ma-

chined, external surface of the slip yoke from dam-

age after propeller shaft removal. If damaged, the

transmission extension seal could be damaged and

cause a leak.

FRONT

REMOVAL

(1) S h if t t h e t r a n sm issio n a n d t r a n sf e r ca se ( i f a p -

p lica ble ) t o N e u t r a l p o sit io n . Ra ise t h e ve h icle . Re -m ove sk id p la t e s (i f e q u ip pe d ) f r om f r a m e , r e fe r t o

Group 13, Frames.

(2) S cr i be a l i gn m en t m a r k s on t h e y ok es a t t h e

t r a n sf er ca s e a n d a x le p in ion . P l a ce m a r ks a t t h e

p in io n sh a f t a n d a t e a ch e n d o f t h e p r o p e lle r sh a f t .

Th e se m a r k s w il l be u se d f or in st a l la t ion r e fe r en ce

(Fig. 2).

(3) Rem ove t h e U -join t st r a p bolt s a t t h e p in ion

shaft yoke.

(4) Re m ove bo lt s f r om t r a n sf e r ca se y o ke a n d r e -

move the propeller shaft.

INSTALLATION

(1) Posit ion the propeller shaft with the yoke refer-

e n ce m a r k s a l ig n ed . I n st a l l t h e p r op elle r sh a f t (F ig .

2).

Re pla cem e n t U -join t st r a p s a n d bolt s m u st be in -

stalled.

(2) Tig h t en t h e U -join t st r a p bolt s a t t h e p in ion

s ha ft t o 1 9 Nm (14 f t . l bs .) t or q u e. Ti gh t en t h et r a n s fer ca s e y ok e b ol t s t o 27 Nm (19.5 f t . lbs.)

torque.

(3) Install skid plates (if equipped), refer to Group

13, F ra mes. Lower t he vehicle.

REAR

REMOVAL

(1) S h if t t h e t r a n sm issio n a n d t r a n sf e r ca se ( i f a p -

plicable) to Neutral posit ion. Ra ise t he vehicle.

(2) S cr ibe a l ign m e n t m a r k s a t t h e p in ion y ok e a n d

at each end of the propeller shaft .

(3) Rem ove t h e U -join t st r a p bolt s a t t h e p in ion

shaft yoke.

(4) S l id e t h e sl ip y ok e of f t r a n sm ission /t r a n sf e r

case output shaft. Remove the propeller shaft (Fig. 3).

INSTALLATION

(1) Slide t he s lip yoke on the tra nsmission/tra nsfer

ca s e ou t pu t s h a f t . Al ig n t h e i n st a l l a t i on r ef er en ce

m a r k s a t t h e p in ion y ok e. I n st a l l t h e p r o pe ller sh a f t

(Fig. 3).

Re pla cem e n t U -join t st r a p s a n d bolt s m u st be in -

stalled.

Fig. 1 Reference Marks on Yokes

Fig. 2 Front Propeller Shaft



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(2) Tighten the U-joint strap bolts to 19 Nm (14 ft.

lbs.) torque.

(3) Lower the vehicle.

Fig. 3 Rear Propeller Shaft



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UNIVERSAL JOINT REPLACEMENT

PRECAUTIONSI t is ve r y im p o r t a n t t o p u t r e f e r e n ce m a r k s o n t h e

yokes before removal or component service (Fig. 1).

Th is w il l a ssu r e cor r e ct p h a sin g a n d e lim in a t e p os-

sible vibrat ion.

SINGLE CARDAN

REMOVAL/DISASSEMBLY

Single carda n universal joints ar e not serviceable. If

worn or leaking, they must be replaced as a unit .

(1) Remove the propeller sha ft . Refer to P ropeller

Shaft Replacement in this Group.

(2) P a i n t or s cor e a l i gn m en t m a r k s on t h e y ok es

an d propeller sha ft for insta llat ion reference.(3) Using a soft drift , tap the outside of the bearing

assembly t o loosen sna p ring.

(4) Remove snap rings from both sides of yoke (Fig.

2).

(5) S e t t h e y o ke i n a n a r b or p re ss or v is e w i t h a

l a r g e s ock et b en ea t h i t . P o s it i on t h e y ok e w i t h t h e

lube fit t ing pointing up (if equipped). Place a smaller

socke t on t h e u p p er bea r in g a sse m bly a n d p r ess i t

t h r o u g h t o r e le a se t h e lo w e r be a r in g a sse m bly (F ig .

3).

(6) I f t h e b ea r i n g a s s em b ly w i ll n ot p ul l o u t b y

h a n d a f t e r p r essin g, t a p t h e ba se o f t h e lu g n e a r i t t o

dislodge.

(7) To remove the opposite bearing, turn the yoke

over and straighten the cross in the open hole. Then

carefully press the end of the cross until the remain-

ing bearing can be removed (Fig. 4).

CAUTION: If the cross or bearing assembly arecocked when being pressed, the bearing assemblywill score the walls of the yoke bore and ruin theyoke.

CLEANING AND INSPECTION(1) C l e a n a l l t h e u n iv er s a l joi n t y ok e b or es w i t h

cleaning solvent and a wire brush.

(2) I n s pect t h e y ok es f or d is t or t i on , cr a c ks a n d

worn bearing assembly bores.

ASSEMBLY/INSTALLATION

(1) App ly e xt r e m e p r e ssu r e (EP ) N .L .G .I . G r a d e 1

or 2 grease to aid in installat ion.

Fig. 1 Reference Marks on Yokes

Fig. 2 Remove Snap Ring

Fig. 3 Press Out Bearing



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(2) P o si t ion t h e cr os s i n t h e y ok e w i t h i t s l ub e

fitting (if equipped) pointing up (Fig. 5).

(3) Place a bearing assembly over the trunnion and

align it with the cross hole (Fig. 6). Keep the needle

bea r in g s u p r ig h t in t h e bea r in g a sse m bly. A n e e d le

roller lying at the bottom will prevent proper assem-

bly.

(4) Pr e ss t h e be a r in g a sse m bly in t o t h e cr o ss h o le

e n ou g h t o in st a l l a sn a p r in g . I n st a l l a sn a p r in g .

(5) R ep ea t s t ep s 3 a n d 4 t o i n st a l l t h e op pos it e

bearing assembly. If the joint is st iff , str ike the yoke

w i t h a s of t h a m m e r t o s ea t t h e n e ed le b e a r in g s. I n -

st a l l a sn a p r in g .

(6) Add grease to lube fitting (if equipped).

(7) I n st a l l t h e p r op eller sh a f t . Re fe r t o P r op elle r


DOUBLE CARDAN (CV)

REMOVAL/DISASSEMBLY

Single carda n universal joints a re not serviceable. Ifworn or leaking, they must be replaced as a unit .

(1) Remove the propeller shaft . Refer to Propeller


(2) P a i n t or s cor e a l i gn m en t m a r k s on t h e y ok es

an d propeller sha ft for insta llat ion reference.

(3) R em ov e a l l t h e b ea r i n g a s s em b ly s n a p r in g s

(Fig. 7).

(4) Pr e ss t h e be a r in g a sse m bly p a r t ia l ly f r o m t h e

outboard side of the center yoke, enough to grasp by

vise jaw s (Fig. 8). B e sure t o remove an y lube fit t ings

t h a t m a y in t e rf er e w it h r e m ova l .

Fig. 4 Press Out Remaining Bearing

Fig. 5 Install Cross In Yoke

Fig. 6 Install Bearing On Trunnion



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(5) G ra sp the protruding bearing by vise jaw s. Tap

the tube yoke with a mallet and drift to dislodge fromth e yoke (Fig. 9).

(6) F li p a s s em bl y a n d r epea t s t eps 4 a n d 5 f or

r e m ovin g t h e op posit e sid e be a r in g . Th is w il l a l low

r em ov a l of t h e cr os s cen t er in g k it a s s em b ly a n d

spring (Fig. 10).

(7) P r e ss t h e r e m a in in g be a r in g a ssem blie s o ut t h e

other cross as described above to complete the disas-

sembly.

CLEANING AND INSPECTION

(1) C le a n a l l t h e U -join t y ok e bo r es w it h cle a n in gsolven t a n d a w ir e br u sh .

(2) I n s pect t h e y ok es f or d is t or t i on , cr a c ks a n d

worn bearing assembly bores.

ASSEMBLY/INSTALLATION

During installation, ensure that the spiders

and yokes are aligned to the reference marks.

(1) Fit a cross into the tube yoke (Fig. 11).

Fig. 7 Remove Snap Rings

Fig. 8 Press Out Bearing

Fig. 9 Remove Bearing From Yoke

Fig. 10 Remove Centering Kit



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(2) P l a ce a b ea r i n g a s s em b ly i n a t u b e y ok e h o le

a n d over a t r u n n ion . K e ep t h e n e ed le bea r in g s u p -right in the bearing assembly (Fig. 12). A needle roller

lying at the bottom will prevent proper assembly. Be

s u r e t o r e m ov e a n y l u be f it t i n gs t h a t m a y i n t er f er e

with removal.

(3) Pr e ss t h e be a r in g a sse m bly in p la ce a n d in st a l l

a snap ring (Fig. 13).

(4) Flip the tube yoke and bearing assembly instal-

la t ion on t h e o pp osit e t r u n n ion . I n st a l l a sn a p r in g

(Fig. 14).

(5) F it t h e ce n t e r y o k e o n t h e r e m a in in g t w o t r u n -

n i on s a n d p re ss b ea r i n g a s s em b li es i n p la c e, b ot h

sides (Fig. 15). Inst all a sna p ring.

(6) I n s t a l l t h e ce nt e ri n g k it a s s em b ly i n si de t h e

ce n t e r y o k e m a k in g su r e t h e sp r in g is in p la ce (F ig .

16). Alig n t h e lu be f i t t in g o n t h e ce n t e r in g k it w it h

the lube fit t ing on t he insta lled cross.

(7) P la ce t w o bea r in g a sse m blies on t h e r e m a in in g

cross (opposite sides). Fit the open trunnions into thecenter yoke holes a nd t he bearing a ssemblies into the

centering kit (Fig. 17). Align the lube fit t ing on th e

cross with the other two lube fit t ings.

(8) P r e ss t h e r em a i n in g t w o b ea r i n g a s s em b li es

into place and insta ll sna p rings (Fig. 18).

(9) Ta p t h e s n a p r i ng s t o a l low t h em t o s e a t i n t o

the grooves (Fig. 19).

(10) Check for proper assembly. Flex the CV joint

beyond center, it should snap over-center in both di-

rections when correctly assembled (Fig. 20).

(11) Add grea se to a ll three lube fit t ings.

Fig. 11 Install Cross In Yoke

Fig. 12 Install Bearing Assembly

Fig. 13 Press In Bearing Assembly




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(12) In sta ll t he propeller sha ft . Refer to P ropellerShaft Replacement in this Group.

Fig. 15 Install Center Yoke

Fig. 16 Install Centering Kit

Fig. 17 Install Remaining Cross




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TORQUE SPECIFICATIONS

Fig. 19 Seat Snap Rings In GrooveFig. 20 Check Assembly

PROPELLER SHAFTS AND U-JOINTS


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