ALLCV

Service Manual
Propeller Shaft
05.02 PROPELLER SHAFT

CONTENTS

CHAPTER - 05

PROPELLER SHAFT
Section Subject Page No.

05.0 DESCRIPTION ........................................................................................................................................... 05.03

05.1 UNIVERSAL JOINT .................................................................................................................................. 05.03

05.2 PROPELLER SHAFT ................................................................................................................................. 05.03

05.3 DATA ...................................................................................................................................................... 05.04

05.4 HANDLING ................................................................................................................................................. 05.05

05.5 REMOVAL .................................................................................................................................................... 05.05

05.6 INSTALLATION ......................................................................................................................................... 05.05

05.7 IMPORTANT INSTALLATION POINT ............................................................................................ 05.05

05.8 MAINTENANCE ........................................................................................................................................ 05.05

05.9 LUBRICATION ........................................................................................................................................... 05.06

05.10 INSPECTION .............................................................................................................................................. 05.07

05.10.0 Propeller Shaft Joints ..................................................................................................................... 05.07
05.10.1 Propeller Shafts ................................................................................................................................ 05.07

05.11 FRONT PROPELLER SHAFT ............................................................................................................... 05.07

05.11.0 Dismantling ........................................................................................................................................ 05.07
05.11.1 Assembly ............................................................................................................................................. 05.08

05.12 REAR PROPELLER SHAFT ................................................................................................................... 05.08

05.12.0 Dismantling ........................................................................................................................................ 05.08
05.12.1 Assembly ............................................................................................................................................. 05.08

05.13 UNIVERSAL JOINTS ................................................................................................................................ 05.08

05.13.0 Dismantling ........................................................................................................................................ 05.08
05.13.1 Assembly ............................................................................................................................................. 05.09

05.14 CENTRE BEARING .................................................................................................................................. 05.09

05.15 TROUBLE SHOOTING .......................................................................................................................... 05.10

 PROPELLER SHAFT 05.03

PROPELLER SHAFT (1410 SERIES)

1. Propeller Shaft - Front

2. Propeller Shaft - Rear
3. Bolt
4. Nut
5. Nut
6. Washer
7. Bolt
8. Centre Bearing Assembly
9. Bracket centre Bearing

05.0 DESCRIPTION 05.1 UNIVERSAL JOINT

The purpose of the propeller shaft is to transmit the
power from the gear box to the rear axle. The
propeller shaft consists of a hollow tube with a fixed
joint at one end, and a slip joint at the other end. At
the fixed joint end a stub shaft is welded to the hollow
tube. The universal joint at this end is fixed to a
sleeve yoke and a flange yoke. The sleeve yoke has
internal splines and slides over the splined shaft thus
adjusting itself to the required length when the vehicle
is in operation. The flanged yoke is serrated on the
flange.
A dust cap with a splined gasket and washer prevents
the entry of dust into the sleeve yoke and the leakage
of the lubricant. A lubricator is provided to lubricate
the splines. The propeller shafts are fitted between the
gearbox and the rear axle. These are supported by a
centre bearing at an appropriate place.
The universal joint consists of a cross with 4 hardened
trunnion arms, over which hardened bearing cups with
needle rollers are fitted. The bearing cups are light push
fit in the yokes and are retained by snap rings. Gaskets
provided over the trunnion arms seal the open ends of
the bearing cups against the leakage of the lubricant and
the entry of dust into the needle rollers.
The lubrication is provided by means of grease nipples.
05.2 PROPELLER SHAFT
Two propeller shafts are installed between gear box and
rear axle supported by a centre bearing.
The shaft between the gear box and the centre bearings
has flange yoke at one end and a companion flange at
the centre bearing end. The shaft between the centre
bearing and rear axle has a flange yoke and a slip joint
at centre bearing end, and a flange yoke and fixed joint
at the rear axle end.
05.04 PROPELLER SHAFT

05.3 DATA
SL.NO FIGURE DESCRIPTION VALUE

1. Diameter of tube ø1 76.2 mm

Thickness of tube X1 2.65 mm

2. Front propeller shaft Without slip joint

3. Rear propeller shaft With slip joint

4. Minimum angular movement of shaft 18°

5. Minimum run out of tube when located

on diameter of flange end 0.5 mm

6. Balance of shaft speed 2500 RPM

Allowed unbalancing with Fixed joint 108 gm/cm

Allowed unbalancing with Slip joint 162 gm/cm

 PROPELLER SHAFT 05.05

05.4 HANDLING 05.7 IMPORTANT INSTALLATION POINT

The front propeller shaft (4) does not have slip joint.
1. Shafts to be transported in the horizontal
The sequence of fitment is given so as to avoid high
position with suitable supports and due care to
stress on gear box output flange end (5) and Universal
avoid impacts and shocks that could damage,
joint (2) of propeller shaft.
the parts, or machined surfaces.

2. Care to be taken during handling to ensure that

balance weights, Dust Cap, Sleeve Yoke Plug,
Grease Nipple and Rubber Seals are not
disturbed or damaged.

3. Shafts to be stored side by side on Wooden

Racks with Flange Yokes resting loosely.

a) Mount front propeller shaft (4) such that centre

Do not stack one shaft over another.
05.5 REMOVAL
Never let the propeller shafts hang from the bearing
after uncoupling one end. Sling to a convenient part of
the chassis. The rear propeller shaft should be
removed before the front one.
1. Disconnect both joints and lift out the rear
propeller shaft.
bearing bracket (3) sits on the cross member (7).
The mounting bolts at this stage in the slotted
holes (6) must be loose.
b) Lift the front end of the Propeller Shaft (5) and
couple firmly to the GearBox output flange.
c) Finally tighten the centre bearing bracket bolts.
05.8 MAINTENANCE

2. Remove the centre bearing from the cross 1. Periodically check that installation of Propeller Shafts
member. as shown in figure and Propeller shafts are not
damaged.
3. Disconnect the front joint at the gear box.
Lower the shaft with centre bearing. 2. Periodically check Flange Yoke securing bolts and
Centre Bearing mounting bolts, for tightness and if
05.6 INSTALLATION necessary retighten them to given torque values

1. Ensure that Flange Faces of Companion Flanges 3. Periodically check Bearing Race Assemblies of
and Flange Yokes are clean and free from dirt, Universal Joints, Ball Bearing of Centre Brg.
grease, oil and antirust and Spigot Dia/Bore are Assembly & Spline Assembly of Slip Joint for noise /
not damaged. play or backlash and if found abnormal or excessive
replace them.
2. Use Recommended Bolts, Spring Washers &
Nuts to install Propeller Shafts on the vehicle. 4. Maintenance of Centre Bearing Assembly is to be
carried out as per instruction.
The Bolts and Nuts to be tightened evenly and
securely to given torque values and the Front &
Rear Propeller Shafts to be installed with the
yokes placed as shown in Figure.
05.06 PROPELLER SHAFT

05.9 LUBRICATION

1. Universal Joints (Greasing pts.) & Slip Joint splines

(Greasing pts.) to be greased after installation of
Shafts on the vehicle and thereafter every 7500
Kms, with lithium based grease of consistency 2
(Grade 2 of IS; 7623 - 1974) for example
“SERVO GREASE - MP” of Indian Oil Corporation
Limited.

2. Universal Joints to be greased till discharge of

Grease takes place from “Rubber Seals” of Bearing
Race Assemblies as shown in Figure. Discharge of
Grease from all Four Rubber Seals of joint will
ensure complete lubrication of joint.

GREASE DISCHARGE FROM SEAL

3. Slip joint Splines to be greased till grease is

discharged from Slip Stub Shaft, Rubber Seal (See
Figure). This will ensure complete lubrication of
Spline Assembly.

4. In the rare event of wear having taken place in

Yoke Ear Cross Holes, the holes will almost
certainly be oval and yoke will have to be
replaced.

EXPLODED VIEW OF PROPELLER SHAFT
05.10 INSPECTION
05.10.0 Propeller Shaft Joints
Before staring the assembly of parts, please stick to the
following inspection procedure.
1. Clean all parts thoroughly.
2. The parts most likely to show signs of wear after
long usage are the bearing assemblies and journal
trunnions. Should looseness in the fit of these
parts, load markings, or distortion be observed,
they must be renewed completely, as no oversize
journals or bearing housings are provided. It is
essential that the bearings are a light drive-fit in
the flange and sleeve yoke lugs. In the rare event
of wear having taken place in the holes in the
yoke lugs, the holes will most certainly be oval,
and the yokes must be renewed.
In case of wear of the holes in a stub ball yoke,
which is part of the tubular shaft assembly, it must
be replaced by a complete tubular shaft assembly.
3. The other parts likely to show signs of wear are
the sleeve yoke and the slip stub shaft. A total
of 0.010 in. circumferential movement measured on
the outside diameter of the spline, should not be
exceeded. Should the stub shaft require renewing,
this must be dealt with in the same way as the
stub ball yoke-i.e., a replacement tubular shaft
assembly must be fitted.
PROPELLER SHAFT 05.07
05.10.1 Propeller Shafts
Original running of propeller shaft will only be assured, if
dismantled parts are reassembled in the same position
and plane as prior to dismantling.
It would be better to check straightness & balance of
Propeller Shaft whose parts have been replaced.
Normally replacement of Stub Ball Yoke and Midship
Stud Shaft Assembly of Front Propeller Shaft Slip Stud
Shaft and Stud Ball Yoke of Rear Propeller Shaft are not
recommended. Instead entire Tubular Shaft Assembly is
to be replaced.
05.11 FRONT PROPELLER SHAFT
With centre Bearing assembly and companion flange
assembly
05.11.0 Dismantling
Support Shaft on V Blocks.
Straighten the legs of Split Pin and pull it out from
slotted Nut.
Unscrew slotted Nut and remove Disc Spring.
Slide off Companion Flange Assembly and Centre Bearing
Assembly from Mid Ship Stud Shaft, if required by
striking them with a Soft Hammer.
Dismantling of Universal joint is to be carried out as per
procedure given.
05.08 PROPELLER SHAFT

05.11.1 Assembly 05.13 UNIVERSAL JOINTS

All Assembly operation to be done in a dust free
atmosphere and all parts used to be clean and free
from dirt and other impurities.
Assemble Universal Joint as per procedure given herein
Assemble Centre Bearing Assembly and Companion
Flange Assembly ensuring that the opposing arrow
marks of Tube and Companion Flange Assembly are
aligned.
Dismantling / Assembly of Joint From / Into
Propeller Shaft.
05.13.0 Dismantling
1. Support shaft on V Blocks (See Figure) and clean
enamel and dirt from Snap Rings and top Bearing
Race Assemblies (or Shim if Shims are fitted).

Assemble Disc Spring with convex face of disc Spring

facing Slotted Nut and screw in Slotted Nut.
The Slotted Nut to be tightened to 30-40 Kgm.,
Torque ensuring that a pair of opposite slots of the
slotted Nut are aligned with the Split Pin hole of Mid-
Ship Stub Shaft.
Also ensure that Rubber Seals of Centre Bearing
Assembly are properly covered by Mudslings on
Companion Flange and Midship Stub Shaft.
Pinch the ears of Snap Ring together by pliers and
remove all the four Snap Rings from the joint. If
Snap Ring does not snap out of groove readily, tap
top of Bearing Race Assembly (or shim if shims are
fitted) by a soft hammer to relieve the pressure
against the ring. (Remove shims if shims are fitted).

It would be better to check straightness and balance of

Propeller Shaft.

05.12 REAR PROPELLER SHAFT

2. Retain the shaft firmly and with the Bearing Race
05.12.0 Dismantling
Assembly to be removed on top, tap the flange
Support Shaft on V Blocks. Straighten out the prongs
yoke with a soft hammer. The Bearing Race
of Dust Cap and pull back Dust cap, Steel Washer
Assembly will begin to emerge until finally the shaft
and Rubber Seal. Sleeve Yoke Assembly can now be
can be turned over and the Bearing Race Assembly
pulled out from Slip Stub Shaft.
removed. Ensure that the Needle Rollers do not
Dismantling of Universal Joints is to be carried out as accidentally spill out of the Bearing Race Assembly.
per procedure given herein.

05.12.1 Assembly
All assembly operation to be done in a dust free
atmosphere and all parts used to be clean and free
from dirt and other impurities.

Assemble Universal Joints as per procedure given herein

Assemble Dust Cap, Steel Washer and Rubber Seal

onto Slip Stub Shaft.

Assemble sleeve yoke Assembly onto slip Stub Shaft

3. The operation described in pt.1.2 is repeated for
ensuring alignment of opposing arrow marks on Sleeve
the opposite Bearing Race Assembly. The
Yoke Assembly and Tube.
unretained Flange Yoke can now be removed from
Fold prongs of Dust Cap into the groove of Sleeve the joint.
Yoke Assembly.

It would be better to check straightness and balance of 4. Repeat operations mentioned in pts. 1.2 & 1.3 and
Propeller Shaft. remove the two remaining Bearing Race Assemblies.

05.13.1 Assembly
If load markings/wear are observed on Journal peg dia,
Needle Rollers or I.D. of Bearing Races of dismantled
Universal Joint, the entire Universal Joint is to be
replaced, because new Journal used with old Bearing
Race Assemblies or New Bearing Race Assemblies used
with old Journal will wear more rapidly making another
replacement, necessary in a short time.
1. All assembly operations to be carried out in a
dust free atmosphere and all parts used should be
clean and free of dirt and other impurities.
2. Insert journal in Flange Yoke cross holes and using
a soft nosed drift slightly smaller than the outside
diameter of Bearing Race Assembly, tap the
Bearing Race Assembly into position by a soft
hammer taking care to avoid accidental spillage of
the Needle Roller.
Fit shim (if Shims are provided) on top of Bearing
Race Assembly and Snap Ring in the Yoke ear
groove.
3. Turn the Flange Yoke by 180° and repeat
operation mentioned in pt.2.2 to insert the second
Bearing Race Assembly in the second yoke ear of
flange yoke.
4. Repeat operations mentioned in pts.2.2 and 2.3 to
insert the remaining two Bearing Race Assemblies
in the second yoke.
5. The articulation of joint should be smooth and
uniform and in case the articulation is stiff, tap
yoke ears with a soft hammer to achieve proper
articulation of joint.
PROPELLER SHAFT 05.09
Sometimes change in the thickness of Snap Ring
and/ or shim (if Shims are provided) may be
required to get proper articulation of joint.
6. The joint should be lubricated after assembly into
Propeller Shaft.
7. It would be better to check balance of Propeller
Shaft after assembly of Universal Joint.
05.14 CENTRE BEARING
The intermediate support bearing is designed to absorb
high frequency vibrations and is intended for use on
commercial vehicles.
The unit utilises a single row ball bearing of the shielded
and sealed off for-life type and no service attention is
therefore required. The bearing is housed within two
similar pressings which extending inwards on either side
of the bearing act as labyrinth seals around the stub
shaft. The cavities created are packed with special water
repellent grease to provide max, protection against
underbody conditions. This sub assembly is sprung with
a “D” shaped cellular rubber moulding which is in turn
suspended within a pressed steel cradle of `U’ section.
The whole assembly is bolted to the chassis cross
member through slotted holes which allow for small
variations due to the production tolerance allowed in
mounting. The bolts themselves apply an initial
compressive load to the rubber and a locking strap adds
additional lateral support, preventing displacement of the
rubber before, during and after assembly to the vehicle.
05.10 PROPELLER SHAFT

05.15 TROUBLE SHOOTING

FAULT POSSIBLE CAUSES REMEDY

Propeller Shaft Vibration/Noise
* Loose drive or coupling shaft
flange bolts
Check all flange bolts. If
loose check for damage to
bolt holes and bolts. Renew
flange bolts and nuts as
necessary.

* Universal joint bearings breaking Check oil universal joints for

up or seized excessive freeplay. If the
joint shows signs of lack of
lubricant of rust coloured
deposits around the spider,
disconnect shaft and check
to ensure joint articulates
freely.

* Drive or coupling shaft out of Check shafts for attached

balance deposits of mud, cement,
tar or similar foreign material.
Clean off as necessary.
Check shafts for evidence
of any balance weights
fitted in production (usually
spot welded in place) hav
ing fallen off. Renew shaft
if necessary

* Drive or coupling shaft bent Check shafts for damage or

damaged
* If vibration has only appeared
since shaft or axle repair of
renewal
distortion. If necessary re
move one axle shaft and
rotate drive line by hand or
engine and check for run
out or shaft flutter. Renew
shaft(s) as necessary.

Warning : Rotating shaft

can be dangerous. You can
snag cloth, skin, air, hands
etc. this can cause serious
injury. Do not work on a
shaft (with or without a
guard) when the engine is
running.

a) Drive line ‘out of phase’ Check that universal joints

are ‘in phase’. If no fault
found reset flanges at 180°
to one another and retest.

b) Flanges not reassembled flush to Check that flanges are

One another assembled correctly. Dis
connect and check flange
faces etc. Stone off any
buffers if present and
reassemble ensuring flush
face to face alignment.

c) Coupling refitted under tension Slacken off support bolt,

reset mounting to relieve
tension and retighten bolts.