Opel Manta Haynes manual.pdf
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113
Chapter 7 Propeller shaft and universal joints
Contents
Fault diagnosis - propeller shaft
5
Rear propeller shaft assembly - renovation (centre bearing
and support, torque tube support blocks)
General description
1
4
Propeller shaft - removal and refitting
2
Universal joints - inspection, removal and repair
3
Specifications
Description
A forward tubular shaft running between a splined sliding joint on
the gearbox output shaft and a rubber bushed universal joint on
the forward end of the rear propeller shaft.
The rear shaft runs in a tubular extension of the final drive
housing. The forward end of the extension - the torque tube - is
held in formation of rubber blocks attached to a beam which is
located transversely underneath the car.
Torque wrench settings
lbs f ft
kg f m
Rear shaft flange to centre universal joint - bolt
11
1.4
Central joint support beam to bodyshell anchor point - bolt 36
5
Support block bolt
29
4
Central joint support to rubber block
15
2
Tube rubber block to torque tube
15
2
Rear shaft - forward end - nut
87
12
from the underside of the car to gain space in the vicinity of the
forward propeller shaft.
4 If it is anticipated that the existing shaft will be refitted - mark
the rear universe joint spider and rear joint yoke (which is
attached to the rear propeller shaft) in order to ensure correct
alignment when befitting.
5 Bend back 'U' bolt nut locking tabs and undo and remove
nuts and washers, and then extract the 'U' bolts.
6 Push the forward propeller shaft slightly forward to permit the
rear end to be lowered clear of the central joint support structure.
(photo)
1 General description
The propeller shaft on the Opel Manta is in two parts: a
forward tubular section and a rearward solid section running in a
tubular extension of the final drive housing. The forward section is
conventional in design, having a universal joint at each end and at
the forward end a splined coupling which slides on the gearbox
output shaft. The rear solid propeller shaft is connected to the
drive pinion shaft by an internal splined sleeve which slides onto
the barrel splined fitting on the pinion shaft. The forward end of
the shaft runs in a bearing seated in a rubber cushion block,
which is itself mounted on the propeller centre joint support. The
rear shaft runs in a tubular member which is secured to the final
drive casing by four bolts. The forward end of the tubular member
rests on two rubber blocks mounted in the propeller shaft central
support. The central joint support is in turn supported by a beam
which runs transversely across the underside of the car, between
anchorages adjacent to those for the rear suspension trailing
arms (Fig 7.1).
2 Propeller shaft - removal and refitting
1 Since it is unlikely that both sections of the shaft will need to
be removed at the same time, the procedures for the separate
removal of those sections follows:
Forward section propeller shaft (Fig 7.2)
2 Begin by raising the vehicle onto chassis stands placed
underneath the rear jacking points. It is necessary to be able to
get comfortably underneath the centre of the car. Remember to
chock the front wheels.
3 Then remove the handbrake cable yoke/tension equaliser
bracket from the brake rod, then detach the exhaust system
2.6 The forward propeller shaft being disengaged from the
rear shaft
114
Chapter 7/Propeller shaft and universal joints
7 Slide the propeller shaft out of the gearbox rear extension
and off its output shaft. Recover the thrust spring from inside the
splined coupling on the front of the propeller shaft.
8 It may be necessary to cover or plug the open end of the
gearbox rear extension to prevent the ingress of dirt or leakage of
gear oil.
9 Refitting the propeller shaft is a reversal of the removal pro-
cedure. Make absolutely certain that if any new parts are being
used - including nuts and bolts - that they are the correct part with
the correct number and are genuine OPEL parts. Coat the
forward coupling splines with EP90 gear oil before fitting the
propeller shaft.
10 Failure of nuts, bolts and other components on the propeller
shaft system could be catastrophic and therefore non-standard
parts should not be used.
11 If the existing propeller shaft is being re-used remember to
align the rear joint spider and the rear shaft yoke according to the
marks made prior to dissembly. The needle bearing cups may be
compressed with a small clamp, so that they will fit into the lugs
on the rear shaft yoke fitting.
Fig 7.1 Exploded view of propeller shaft components (Sec 1)
1 Forward propeller shaft
4 U bolts retaining spider to
8 Centre bearing rubber
rear axle extension
(tubular)
yoke fitting
support
12 Torque tube support
2 Rear propeller shaft
5 Universal joint spider
9 Centre bearing
rubbers
(solid)
6 Forward universal joint and 10 Centre bearing assembly 13 Rear shaft end thrust
3 Rear shaft forward joint
splined coupling
support beam
rubber blocks
yoke fitting
7 End thrust spring
11 Torque tube -
14 Spacer
Fig 7.2 The forward propeller shaft (Sec 2)
115
Chapter 7/Propeller shaft and universal joints
Rear section propeller shaft
12 The rear section of the shaft is removed complete with the
tubular extension to the final drive housing and the central joint
support beam.
13 Begin by raising the vehicle onto chassis stands placed
under the rear axle end fittings.
14 Remove the handbrake cable yoke/tension equaliser bracket
from the handbrake rod. Detach the return spring from the brake
rod.
15 Next detach the exhaust pipes from the underside of the
vehicle to give extra access to the forward and rearward sections
of the propeller shaft.
16 To ensure correct alignment when reassembling the
propeller shaft - mark the rear universal joint spider and the yoke
splined onto rear shaft.
17 Undo and remove the nuts and 'U' bolts which secure the
spider to the yoke and lift the forward section to one side.
18 Bring a jack underneath the central joint support beam and
bring into contact with that beam to apply a little force to the
beam. Now the nuts and bolts securing the central beam to the
bodyshell anchorages may be undone and removed.
19 Detach the brake hydraulic line support bracket from the
tubular extension of the final drive unit.
20 Lower the central joint support beam just a little and then
unbolt the tubular extension (torque tube) from the flange on the
final drive housing.
21 The whole rear shaft assembly may now be removed from
the underside of the car.
22 The refitting of the rear section of the propeller shaft is a
reversal of the removal sequence described.
23 The comments made in paragraphs 9, 10 and 11 earlier in
this Section apply equally to the rear propeller shaft Installation.
24 If the brake hydraulic system was disturbed, bleed the rear
brakes and in any event check the adjustment of the handbrake.
Both tasks are described in Chapter 9 of this manual.
25 Remember to tighten all vital nuts and bolts to the torques
specified at the beginning of this Chapter.
Reassembly
7 Thoroughly clean out the yokes and journals.
8 Fit new seals and retainers on the spider journals, place the
spider on the propeller shaft yoke and assemble the needle
rollers into the bearing cups retaining them with some thick
grease.
9 Fill each baring cup about 1/3 and fill with Castrol LM
Grease. Also fill the grease holes in the journal spider with grease
taking care that all air bubbles are eliminated.
10 Refit the bearing cups on the spider and tap the bearings
home so that they lie squarely in position.
11 Using a centre punch peen over the end of the bearing cup
bores to stop the cups from working out.
4 Rear propeller shaft assembly - renovation
1 There are two sets of rubber supports in the centre propeller
shaft joint area; firstly there is the block which supports the rear
shaft forward end support bearing and secondly there are the two
blocks which support the forward end of the torque tube in the
rear propeller shaft.
2 The shaft support bearing, the shaft and the blocks cannot
be removed in situ, therefore begin by removing the rear section
of the propeller shaft as described in the previous Section.
3 With the rear propeller assembly on a bench, undo and
remove the nut which retains the centre universal joint yoke onto
the forward end of the shaft. Restrain the shaft by holding the
yoke with OPEL tool 'J8614' or with a bar suitably bolted to the
yoke fitting.
4 Once the nut has been removed, the yoke may be gently
tapped off the shaft with a soft mallet. If it is tight a universal puller
should enable it to be removed.
5 The propeller shaft may now be driven out of the forward
bearing and the torque tube using a soft mallet (Fig 7.3).
Centre bearing and rubber support
6 Once the shaft has been removed from the assembly the
centre bearing may be pulled from its rubber support complete
with its metal casing. The rubber cushion support is retained in
the central joint support by tabs which have been bent inwards
around the outer lips of the rubber moulding. Once those tabs
have been eased back off the rubber, the moulding can be
extracted from the joint support fitting (Fig 7.4).
Refitting the two items follows the reversal of the removal
sequence. The space in front of the centre bearing must be
packed with water resistant grease (Fig 7.5).
3 Universal joints - inspection, removal and repair
1 Wear in the needle roller bearings is characterised by
vibration in the transmission, 'clonks' on taking up the drive, and
in extreme cases of lack of lubrication, metallic squeaking, and
ultimately grating and shrieking sounds as the bearings break up.
2 It is easy to check if the needle roller bearings are worn with
the propeller shaft in position, by trying to turn the shaft with one
hand, and the other hand holding the rear flange when the rear
universal is being checked, and the front coupling when the front
universal joint is being checked. Any movement between the
propeller shaft and the front, or rear couplings is indicative of
considerable wear. If worn, the old bearings and spider will have
to be discarded and a repair kit, comprising new universal joint
spiders, bearings, oil seals, and retainers purchased. Make sure
this kit is available to you before dismantling. Check also by trying
to lift the shaft and noticing any movement in the splines.
3 Test the propeller shaft for wear, and if worn it will be
necessary to purchase a new forward half coupling, or if the
yokes are badly worn, an exchange half propeller shaft. It is not
possible to fit oversize bearings and journals to the trunnion
bearing holes.
Torque tube support blocks
7 Having already removed the propeller shaft and its
associated parts - note, the centre bearing and its support
moulding
need not
be removed.
Dismantling
4 Clean away all traces of dirt and grease from the universal
joint yoke. Using a very small and sharp chisel remove the metal
that has formed a lip over the bearing cup faces by peening. This
will take some time and great care.
5 Hold the propeller shaft and using a soft faced hammer tap
the universal joint yoke so as to remove the bearing cups by
'shock' action.
6 Remove all four bearing cups in the manner described and
then free the propeller shaft from the spider.
Fig 7.3 The rear propeller shaft removal from torque ass-
embly (Sec 4)
116
Chapter 7/Propeller shaft and universal joints
Fig 7.4 The centre bearing removal from the support rubber
(Sec 4)
Fig 7.5 A section of the centre bearing assembly (Sec 4)
Fig 7.6 The arrows indicate the bolts retaining the torque
tube support to the centre bearing support member (Sec 4)
8 Clamp the torque tube in a vice and undo and remove the
bolts which secure the rubber cushion blocks to the support
member (Fig 7.6).
9 Once the bolts have been removed, the support may be
pulled clear to expose the two tube cushion blocks.
10 Inspect the blocks, if the surface is cracked or the bond
between the rubber and the metal bushing falling, replace both
blocks.
11 New blocks should be screwed into the torque tube and
tightened to 29 lb f ft.
12 Refit the support member so that the torque tube and one
rubber block is in the right position approximately. Then lever the
second block into place in the support member using a strong
screwdriver (Fig 7.7).
13 Tighten the bolts securing the blocks to the support to a
torque of 15 lb f ft.
Fig 7.7 Levering the torque tube and its rubbers into the
centre support member (Sec 4)
5 Fault diagnosis - propeller shaft
1 The main symptom of a faulty propeller shaft is a severe low
frequency vibration, the intensity of which is variable with the road
speed of the car. The vibration will be unaffected by whether the
car is accelerating or decelerating.
2
The faults can be in several places:
Reassembly of the rear propeller shaft unit
14 The propeller shaft should be inserted into the rear end of
the torque tube and driven through the forward support bearing
with a soft mallet. Be careful not to strain the rubber support of
the forward bearing.
15 Refit the universal joint yoke: use a soft mallet again, to drive
the yoke fitting home on the splines on the shaft.
16 Restrain the yoke with either OPEL tool 'J8614' or an
improvised tool bolted to the yoke fitting and secure the yoke with
a
new
self-locking nut on the end of the shaft. Tighten the nut to a
torque of 87 lb f ft.
17 Refit the rear propeller shaft to the vehicle as detailed in
Section 2, of this Chapter.
i)
One or both of the universal joints.
ii)
The forward joint sliding splines on the gearbox output
shaft
iii)
A worn centre support bearing.
iv)
Deterioration of centre bearing suppor t rubbers
v)
Out of balance forward propeller shaft, eg; a bent shaft or
shaft unevenly coated with paint or underseal.
3 The propeller shaft is finely balanced and the smallest
noticeable amounts of wear can excite severe vibration
4 Check for wear of the bearings and joints by gripping each
side of the bearing or joint and try to force radial or axial relative
movement as appropriate.
117
Chapter 8 Rear axle
Contents
Axle-shaft, bearings and oil seals - removal, inspection and
refitting
General description
1
3
Limited slip differential - description and checking
6
Differential assembly - removal, dismantling, reassembly
and refitting
Pinion shaft oil seal - removal and replacement
4
5
Rear axle - removal and refitting
2
Specifications
Axle type
Semi floating hypoid
Axle ratio
Standard
Special equipment
16N engine (pre chassis No 2453081)
3.70:1
-
16N engine (post chassis No 2453081)
3.67:1
-
16S engine (except Rallye)
3.67:1
-
16S engine (Rallye)
3.89:1
3.44:1
19S engine (all models + Rallye automatic)
3.44:1
3.67:1
19S engine (Rallye manual)
3.67:1
3.89:1
19 US engine (aIl models + Rallye automatic)
3.44:1
-
19 US engine (Rallye manual)
3.67:1
-
Oil capacity
16N engine models prior to chassis No 2453081
1.1 Imp pints, 1.4 US pints, 0.65 litre
All other models
1.9 Imp pints, 2.3 US pints, 1.1 litre
Crownwheel and pinion
Pinion bearing preload
New bearings
7 to 13 lb f inch (0.49 to 0.91 kg f cm)
Reused bearing
5 to 8 lb f inch (0.35 to 0.56 kg f cm)
Pinion depth setting
0.002 to -0.001 inch (0.05 to -0.02 mm)
from pinion marking using the following shims:-
Thickness (inches) Number of notches in circumference
0.0097 Flattened on one side
0.0098 0
0.0108 1
0.0118 2
0.0128 3
0.0138 4
0.0148 5
Clearance between differential cage and side gears a maximum 0.000"
Use the following shims:-
Thickness (inches)
Number of notches in circumference
0.039
0
0.041
1
0.043
1
0.045
3
0.047
2
0.049
5
0.051
3
0.053
7
0.055
8
Axle-shaft bearing seat: maximum radial runout
0.002 in. (0.05 mm)
Axle-shaft flange lateral runout:
0.004 in. (0.10 mm) Max at greatest Diameter
Crownwheel gear, maximum lateral runout
0.003 in. (0.07 mm)
Crownwheel gear/drive pinion backlash
0.004 to 0.008 in. (0.10 to 0.20 mm)
Differential side bearing preload
New bearings
20 to 30 lb f in. (1.40 to 2.10 kg f mm)
Used parings
10 to 20 lb f in. (0.70 to 1.40 kg f mm)
with the following shims:
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