SECTION 4C - PROPELLER SHAFT AND UNIVERSALJOINTS

CAUTION:This vehicle will be equipped with a Supplemental Restraint System (SRS). An SRSwill consist of either seat belt pre-tensioners and a driver's side air bag, or seat beltpre-tensioners and a driver's and front passenger's side air bags. Refer toCAUTIONS, Section 12M, before performing any service operation on or around anySRS components, the steering mechanism or wiring. Failure to follow the CAUTIONScould result in SRS deployment, resulting in possible personal injury or unnecessarySRS system repairs.

CAUTION:This vehicle may be equipped with LPG (Liquefied Petroleum Gas). In the interests ofsafety, the LPG fuel system should be isolated by turning ‘OFF’ the manual servicevalve and then draining the LPG service lines, before any service work is carried outon the vehicle. Refer to the LPG leaflet included with the Owner's Handbook fordetails or LPG Section 2 for more specific servicing information.

CAUTION:Whenever any component that forms part of the ABS or ABS/ETC (if fitted), isdisturbed during Service Operations, it is vital that the complete ABS or ABS/ETCsystem is checked, using the procedure as detailed in 4. DIAGNOSIS, ABS orABS/ETC FUNCTION CHECK, in Section 12L ABS & ABS/ETC.

1. GENERAL DESCRIPTIONThe propeller shaft assembly used on all VT model vehicles is a two piece tubular design, refer to Figure 4C-1.For all VT models except those fitted with a manual transmission, each end of the propeller shaft, has a needlebearing universal joint connected to a slip yoke at the transmission end and a flange at the rear axle end.Drive is transmitted between the two halves of the propeller shaft through a constant velocity joint. A fully sealed ballbearing, mounted in a reinforced rubber cup, supports the propeller shaft assembly in the centre location. Thiscentre bearing rubber cup is supported in a cup guide and attached to a carrier, which in turn, is bolted to thevehicle underbody.The constant velocity joint has axial movement to allow fore and aft movement of the rear propeller shaft during therear suspension movement.The constant velocity joint, centre bearing, propeller shaft rear universal joint and flange are common for allapplications.The universal joint/s, constant velocity joint and centre bearing are lubricated for life and do not require any periodiclubrication.Those vehicles fitted with the V6 engine and manual transmission have a rubber coupling that bolts directly to therear transmission output flange.When the V8 engine with manual transmission is fitted to a VT model vehicle, an hydraulically dampened rubbercoupling replaces the front, needle roller bearing universal joint. The coupling bolts to a flange on the front propellershaft and a flange on the transmission slip joint.

Figure 4C-1

2. SERVICE OPERATIONS

2.1 PROPELLER SHAFT

REMOVECAUTION:Whenever any component that forms part ofthe ABS (if fitted) is disturbed during ServiceOperations, it is vital that the complete ABSsystem be checked, using the procedure asdetailed in DIAGNOSIS, ABS FUNCTIONCHECK, in Section 12L ABS & ABS/ETC.1. Using a floor jack under the centre of the rear

axle housing, jack up rear of vehicle and placesafety stands under body rear jacking points.Refer to Section 0A GENERALINFORMATION for location of jacking points.

2. Disconnect exhaust system from rear ofcatalytic converter (V6 engine) or converters(V6 Supercharged and V8 engines). Discardgaskets on the V6 Supercharged and V8flanges.

NOTE:Only one flange of the V6 Supercharged/V8 systemis shown.

Figure 4C-23. Remove the two retainers from the top posts

and discard. Disconnect exhaust systemsupport rings from rear hanger of the rearmuffler. Both V6 and V8 arrangements are thesame.

Figure 4C-3

4. Remove muffler support to rear crossmemberretainers (2 places-V6, 4 places-V6Supercharged and V8) and discard.

5. Lift up intermediate section of exhaust systemand remove intermediate muffler supportrubbers. Remove intermediate and rearsections of exhaust system from vehicle.

Figure 4C-4For VT Models Fitted with V8 Engine and Manual Transmission6. Support weight of transmission assembly on a

transmission jack.7. Use a sharp scriber to mark the exact location

of the crossmember to the side frames(arrows), before loosening any fasteners.Also scribe around the rear mounting washers,marking their location on the alloycrossmember.

IMPORTANT:These steps are critical to the correct powertrainalignment on reassembly. If not carried out, thenvehicle vibration and/or handling problems couldresult!

Figure 4C-58. Remove the nut securing the vehicle speed

sensor pick-up bracket to the rear of thetransmission and secure to one side, using tiewire.

Figure 4C-6

9. Remove the four crossmember to side framebolts (3) and spacers (1). Unless required forsome other purpose, the crossmember (2) torear mount nuts (4) do not need to bedisturbed.

10. Lower the transmission to provide clearancefor the propeller shaft to be removed from thevehicle.

NOTE:Neither the transmission jack nor propeller shafthave been shown in the illustration for clarity of thecrossmember orientation.

Figure 4C-7For VT Models Fitted with V6 Engine and Manual TransmissionNOTE:To gain access to the front, flexible rubber couplingbolts and nuts, it is recommended that the twinexhaust pipe/catalytic converter are removed.11. Disconnect the wiring harness connectors

from each of the two oxygen sensors (1).

Figure 4C-812. Remove the twin exhaust pipe (5) and catalytic

converter assembly (4) and the support rubber(6) at the rear of the transmission. Carefullylower and remove the exhaust pipes from thevehicle, taking care not to damage the exhaustgas oxygen sensors, in the process.

Figure 4C-9

13. Remove propeller shaft flexible rubbercoupling to output flange attaching nuts.Discard removed nuts.

Figure 4C-10All VT Models14. Remove centre bearing carrier to underbody

reinforcement bolts and spacers, if fitted.NOTE:For correct reassembly, take particular note of anyspacer arrangement that may be fitted, observingany side-to-side differences and the orientation ofthe offset bracket.

Figure 4C-1115. Remove bolts and nuts holding propeller shaft

rear universal joint flange to pinion flange.Disengage rear universal joint flange frompinion flange.

NOTE:The two flanges have paint alignment marks thatare assembled as close together as possible. If themarks are not visible, scribe a line on both flangesto enable the propeller shaft to be installed in theoriginal position.16. Remove propeller shaft by pulling it toward the

rear of vehicle to either disengage the rubbercoupling or the front slip joint yoke fromtransmission.

Figure 4C-12

For VT Models with a Sliding YokeNOTE 1:Take care to protect the outer diameter of the frontyoke. Nicks or abrasions will damage thetransmission extension seal during reassembly andresult in lubricant leakage past the seal.NOTE 2:For VT Models fitted with the V8 engine andManual Transmission, take particular care not todamage any teeth on the vehicle speed sensortoothed ring, installed onto the sliding yoke. Anydamage to these teeth will cause the sensor tomalfunction.NOTE 3:Insert a suitable plug in the end of the transmissionrear extension to prevent loss of transmissionlubricant.

REINSTALLInstallation is the reverse of removal proceduresnoting the following points:1. Remove any foreign matter that may have

adhered to the front universal joint yoke andlubricate with transmission lubricant. Guidepropeller shaft over park brake cable andinsert yoke on to transmission mainshaft.

NOTE:If the propeller shaft is fitted with a toothed, speedsensor ring (V8 with Manual Transmission) takeparticular care not to damage the teeth, duringinstallation.2. Before attaching propeller shaft rear universal

joint flange to pinion flange, align marks onpinion flange and rear universal joint flange (ormarks made on removal), refer to Figure 4C-12.

3. Care must be taken to use only genuine boltsand nuts. Tighten propeller shaft rearuniversal joint flange to pinion flange bolts tothe correct torque specification.

PROPELLER SHAFT REARUNIVERSAL JOINT FLANGE 55 - 65TO PINION FLANGE BOLT NmTORQUE SPECIFICATION

4. Clean threads of centre bearing carrier tounderbody reinforcement bolts and underbodyweld nuts with a suitable cleaning solvent.

NOTE:Replace micro-encapsulated bolts if they havebeen removed three times. If in doubt, replacementis recommended. If not replacing the bolts,apply Loctite 242 or an equivalent threadsealant to the cleaned threads.5. Install centre bearing carrier with the correct

orientation (refer to Figure 4C-11).

6. If fitted, ensure that the centre bearing carrierspacers are in correct position, as noted onremoval (refer to Figure 4C-1) and tightencentre bearing carrier to underbodyreinforcement bolts to the correct torquespecification.

CENTRE BEARING CARRIER TOUNDERBODY REINFORCEMENT 20 - 35 NmBOLT TORQUE SPECIFICATION

VT Models with V8 Engine and ManualTransmission7. With this powertrain combination, when the

propeller shaft is installed into the rear of thetransmission, support the propeller shaftcentre bearing while the transmission israised. Loosely install the four rearcrossmember bolts and the centre bearingbracket retaining bolts, taking note of anyspacers that may be fitted.

8. Align the rear crossmember with the scribedalignment marks made prior to removal, thentighten the four bolts to specification.

REAR CROSSMEMBER TO SIDEFRAME MEMBER BOLT 50 - 65 Nm

TORQUE SPECIFICATION

9. install the vehicle speed sensor bracket bolt tothe rear of the transmission and tighten tospecification.

SPEED SENSOR BRACKET 15 - 20BOLT TORQUE SPECIFICATION Nm

VT Models with V6 Engine and ManualTransmission10. Lubricate the transmission output shaft spigot

with molybdenum disulphide grease to HoldenSpecification HN1271.

11. Install NEW rubber coupling to transmissionoutput flange retaining nuts and tighten to thecorrect torque specification.

RUBBER COUPLING TO OUTPUTSHAFT FLANGE RETAINING NUT 74 - 80 Nm

TORQUE SPECIFICATION

12. Replace the exhaust system as follows;a. With V6 engined vehicles, install the twin

exhaust pipes to the manifolds, reconnectthe exhaust gas oxygen sensor wiringleads and tighten the nuts to the specifiedtorque.

EXHAUST PIPE FLANGE TOEXHAUST MANIFOLD NUT V6 Engine:TORQUE SPECIFICATION 18 35 Nm

b. Supercharged and V8 engined vehicles,ensure the catalytic converter flange isclean and free from any gasket material.With V6 engined vehicles, check that thecatalytic converter to intermediateexhaust pipe bolts springs and sealingring are all in a serviceable condition.

c. Reinstall exhaust system, using a newgasket (V6 Supercharged and V8engined vehicles) at the catalyticconverter and new hanger retainers forthe muffler support to rear crossmember.Tighten intermediate exhaust pipe toconverter attaching bolts to the correcttorque specification.

INTERMEDIATE EXHAUST PIPETO CATALYTIC CONVERTER All Engines:

BOLT TORQUE SPECIFICATION 40 - 50 Nm

d. Check exhaust clearances as detailed in Section 8B EXHAUST SYSTEM.

All VT Models with a Sliding Yoke13. If transmission lubricant leaked from the rear

extension when the propeller shaft wasremoved, check transmission lubricant leveland top up as necessary. Refer to Section 0B LUBRICATION AND SERVICEfor lubricant specifications.

2.2 UNIVERSAL JOINTS

REMOVENOTE 1:The following Operation is only suitable for thereplacement of a universal joint, as brinelling of theneedle roller bearings will result from the removalprocess.NOTE 2:With vehicles fitted with the V8 engine and manualtransmission, the toothed speed sensor ring isswaged to the front sliding yoke and is not servicedas a separate component. For this reason,particular care must be taken when removing andhandling the propeller shaft to avoid damaging theteeth.NOTE 3:While the majority of illustrations show the frontuniversal joint, the procedure is the same for bothuniversal joints.1. Remove propeller shaft. Refer to

2.1 PROPELLER SHAFT in this Section.2. Mount propeller shaft in vice equipped with

soft jaws. Remove bearing cap retaining snaprings from grooves at inner ends of bearingcaps.

Figure 4C-133. Remove bearing caps from ends of the

propeller shaft assembly as follows:a. Support front universal joint yoke, or rear

universal joint flange ears on open jawsof a vice.

b. Tap propeller shaft adjacent to bearingcap with a hammer so that universal jointspider forces bearing cap out.

Figure 4C-14

4. Pull dislodged bearing cap from front or rearuniversal joint, as shown.

5. Rotate propeller shaft assembly 180° so thatears on opposite side of yoke, or flange, reston the soft jaws in the vice.

6. Remove second bearing cap from propellershaft as per steps 3 and 4.

7. Separate yoke or flange from universal jointspider.

Figure 4C-158. Remove bearing caps from yoke or flange by

resting exposed ends of spider on the vice,and removing bearing caps as previouslydescribed.

9. Remove the spider from the yoke or flange.10. Thoroughly clean yoke or flange and propeller

shaft universal joint bearing cap bores.Check bearing cap bores and remove anyburrs.

Figure 4C-16

REINSTALLBefore installing universal joint, note the following:

a. Cleanliness is of prime importance toensure maximum universal joint life.

b. Do not allow any needle rollers tobecome dislodged. Install bearing caps inthe upright position.

c. Universal joint assemblies are prepackedwith lubricant and do not require anyfurther lubrication.

d. Take care not to damage bearing capseals during installation. Gently easebearing caps into their bores duringassembly.

1. Remove bearing caps from spider.2. Position spider in yoke or flange. Hold spider

to one side in yoke or flange and position abearing cap on the end of spider.

3. While holding spider in bearing cap, tapbearing cap into yoke or flange until bearingcap snap ring groove is fully visible. Installsnap ring into groove.

Figure 4C-17

4. Turn yoke or flange around and installopposite bearing cap by positioning spider intobearing cap to prevent needle rollers frombeing dislodged.

Figure 4C-185. To fully install second bearing cap, position

yoke or flange in vice with two of the olduniversal joint bearing caps, as shown.Squeeze new bearing caps into position usingthe vice jaws.

NOTE:Ensure that the two old bearing caps are positionedcentrally on the new bearing caps, and not upagainst the edge of the flange or yoke.6. Install second snap ring.7. Install spider and yoke or flange assembly to

propeller shaft.8. Install remaining bearing caps and snap rings

as previously described.Figure 4C-19

9. While supporting the universal joint in onehand to minimise any brinelling effect, tappropeller shaft, yoke and flange ears with ahammer and ensure that all bearing cap snaprings are seated correctly in bearing capgrooves and that universal joints are free tomove in all directions.

Figure 4C-2010. Reinstall propeller shaft as per

2.1 PROPELLER SHAFT, in this Section.

2.3 FRONT FLEXIBLE JOINT

REPLACEV8 Engine, Manual Transmission1. Remove propeller shaft. Refer to

2.1 PROPELLER SHAFT in this Section.2. Insert a suitable lever between the flexible joint

(3) and the propeller shaft yoke (1) to securethe assembly.

3. Loosen, then remove the three bolts (7)holding the flexible joint (3) to the front slidingyoke (1). Carefully remove the yoke and set toone side to prevent accidental damage to thetoothed speed sensor ring.

4. Using a back-up spanner on the remainingthree bolt heads (5), remove the retaining nuts(2) from the front of the flexible joint anddiscard them. Remove each bolt, taking noteof the spacer (4) between the front of thepropeller shaft (6) and the flexible joint.

5. Install a replacement flexible joint and fit thebolts and spacers to secure the propeller shaftto the joint. Using new nuts (2), tighten each tothe correct torque specification.

PROPELLER SHAFT TOFLEXIBLE JOINT NUT 74 - 80 Nm

TORQUE SPECIFICATION

6. Apply thread sealant such as Loctite 242 orequivalent to the cleaned threads of theremaining three bolts (7). Install the bolts intothe front sliding yoke (1) and tighten to thecorrect torque specification.

FLEXIBLE JOINT BOLT TO FRONTSLIDING YOKE 74 - 80 Nm

TORQUE SPECIFICATION

Figure 4C-21

V6 Engine, Manual Transmission1. Insert a suitable lever between the flexible

joint and the propeller shaft yoke to secure theassembly.

2. Using a back-up spanner on the three boltheads, remove the retaining nuts and discardthem.

3. Install a replacement flexible joint, fit the boltsand new nuts, tightening each to the correcttorque specification.

PROPELLER SHAFT TOFLEXIBLE JOINT NUT 74 - 80 Nm

TORQUE SPECIFICATION

2.4 CONSTANT VELOCITY JOINTThere are two repair kits available from authorisedHolden parts outlets, for constant velocity jointrepairs:

a. A DUST SHIELD KIT, which contains dustshield, gasket, strap, and tubes of greaseand sealant.

b. A CONSTANT VELOCITY JOINT KIT,which contains the same items as in theDUST SHIELD KIT, plus the constantvelocity joint and appropriate retainingcirclips.

REMOVE

Figure 4C-221. Remove propeller shaft. Refer to

2.1 PROPELLER SHAFT in this Section.2. To ensure correct alignment of parts at

reassembly, scribe an aligning mark onconstant velocity joint and two propeller shafthalves.

3. Remove Allen head screws and lock platesholding rear propeller shaft half to constantvelocity joint.

Figure 4C-23

4. Using a hammer and a brass drift, tappropeller shaft companion flange evenly fromconstant velocity joint.

Figure 4C-245. Remove constant velocity joint rear retaining

circlip.

Figure 4C-256. Remove dust shield strap. Using a hammer

and brass drift, remove dust shield fromconstant velocity joint.

7. Remove centre bearing carrier to centrebearing cup attaching bolts and nuts, removecarrier.

Figure 4C-26

8. Pull back constant velocity joint outer race.Install suitable press plates, such as J22912-01 or equivalent, between dust shield andconstant velocity joint, to support inner jointrace. Press shaft from constant velocity joint.

Figure 4C-279. Remove thrust washer and dust shield from

propeller shaft.10. Clean old gasket material from dust shield and

constant velocity joint mating surfaces.

Figure 4C-28

DISASSEMBLENOTE:Complete disassembly of the constant velocity jointis not recommended. The internal components area precision fit and develop their own characteristicwear patterns. Intermixing components could resultin looseness, binding and/or subsequent prematurefailure of the joint.If disassembly must be attempted, then it is vitalthat the following procedure is carefully followed.1. Make an aligning mark on inner race, ball

guide and outer race with a daub of paint, asshown.

NOTE:The groove in the inner race, the larger chamfer inthe ball guide and the step in the outer race (step isfor the dust shield to joint gasket), all face towardthe front of the propeller shaft.

Figure 4C-28

2. Pivot inner race and ball guide at 90° to centreline of outer race as shown, and lift inner raceand ball guide from outer race.

Figure 4C-293. Using a screwdriver, lever balls from guide, as

shown.KEEP BALLS IN ORDER FOR RE-ASSEMBLY.

4. Pivot inner race at 90° to centre line of ballguide and lift inner race from ball guide.

Figure 4C-30

INSPECT1. Inspect grease in joint, and if obviously

contaminated and/or been subjected to dirtingress, the joint has in all likelihood suffereddamage and should be replaced.If inspection reveals that the joint has not beencontaminated, clean joint by soaking in asuitable cleaning solvent.

2. Once grease has been removed, inspectinternal components by tilting inner race to oneside to expose each ball.Replace joint assembly if there is severepitting, galling, play between balls and thecage windows, any cracking or damage tocage, pitting or galling or chips in raceways. Figure 4C-31

REASSEMBLENOTE 1:During the removal, cleaning, inspection orreplacement of a constant velocity (CV) joint, it ispossible for the joint to become disassembled.Should an inadvertent disassembly of a constantvelocity joint occur, and notwithstanding the earlierrecommendation, it is possible to reassemble theCV joint, provided the following procedure isfollowed EXACTLY.NOTE 2:Under no circumstances may components fromone constant velocity joint be mixed withcomponents from another CV joint.An exploded view of the constant velocity joint is asshown. Note the identification groove on the outerrace and the identification step on the inner race.

Figure 4C-321. Place the inner race into the cage and position

centrally within the cage.

Figure 4C-33

2. Place the inner race and cage into the outerrace. Make sure that the identificationmarkings on both the inner and outer racesare on opposite sides of the assembly, asshown.

Figure 4C-343. Align the thick sections on the outer race, with

the narrow ones on the inner race.

Figure 4C-35

4. Tilt the cage and inner race as shown, and fitone ball.Repeat this process for the remaining fiveballs.

Figure 4C-365. When assembly of the CV joint is complete,

check for plunge movement as shown. If NOplunge movement can be achieved, thenthe constant velocity joint has beenINCORRECTLY assembled.

If such a situation occurs, the CV joint must bedisassembled and the assembly processrepeated until such time that the requiredplunge movement is achieved.

Figure 4C-37

REINSTALLInstallation is the reverse of removal procedure,noting the following points:1. Cleanliness of constant velocity joint and

associated parts is of prime importance toensure maximum life of joint assembly.

2. Inspect dust shield to ensure there is nodamage which will allow foreign matter entry.

3. Pack the constant velocity joint with thelubricant supplied in either of the two availableRepair Kits. Work joint by hand so as todistribute grease onto all surfaces inside joint.

4. Install new gasket to front of constant velocityjoint.

5. Clean mating surfaces of constant velocityjoint, dust shield and rear propeller shaftcompanion flange.

6. Apply a bead of Loctite 510 High TemperatureGasket Eliminator sealant or equivalentproduct (Holden's Specification HN1593) todust shield mating surface on the constantvelocity joint, refer to Figure 4C-22 for thelocation.

7. Ensure that scribed lines made on removal,are aligned.

8. Press constant velocity joint onto shaft using asuitable size socket or tube. Ensure thatsocket or tube presses on inner race of joint.

NOTE:During this pressing operation, ensure that the earsof the front propeller shaft (and not the front yoke)are resting on the press plates.9. Clean threads in rear propeller shaft

companion flange and six Allen head screws. 10. Coat spigot area of propeller shaft companion

flange and six Allen head screw threads withLoctite 510 High Temperature GasketEliminator sealant or equivalent product(Holden's Specification HN1593), refer toFigure 4C-22.

11. Tighten six Allen screws to the correct torquespecification.

CONSTANT VELOCITY JOINT TOREAR PROPELLER SHAFT SCREW 35 - 40 Nm

TORQUE SPECIFICATION

12. Reinstall propeller shaft. Refer to2.1 PROPELLER SHAFT in this Section.

Figure 4C-38

2.5 CENTRE BEARING ASSEMBLYNOTE 1:This bearing cannot be removed from the propellershaft without causing damage to the ball race andrear dust slinger. New parts must be installed whenthe propeller shaft is being reassembled.NOTE 2:The replacement centre bearing kit contains frontand rear dust slingers, centre bearing and rubbercup assembly and centre bearing retaining circlip.

REMOVE1. Remove propeller shaft, refer to

2.1 PROPELLER SHAFT in this Section.2. Remove constant velocity joint, refer to

2.3 CONSTANT VELOCITY JOINT in thisSection.

3. Remove the two bolts and nuts securing theupper and lower cup guides to the centrebearing carrier, bend back the retaining tabs (ifbent over) and separate cup guide halves fromcentre bearing.

NOTE:For correct reassembly, pay particular attention toany spacer arrangement that may be fitted, notingany side-to-side differences.

Figure 4C-394. Using a hammer and a suitable punch,

remove centre bearing rear slinger, refer toFigure 4C-41.

NOTE:Once removed, the slinger must be discarded anda new one installed on reassembly.

Figure 4C-405. Remove centre bearing retaining circlip.

Figure 4C-41

6. Using suitable press plates, such as Tool No.J22912-01 or equivalent, support centrebearing and rubber cup mounting assembly asclose as possible to propeller shaft, presspropeller shaft from centre bearing.

NOTE:Take care not to damage the large diameter slingerwhich is fixed to the front propeller shaft tube.

Figure 4C-427. Remove centre bearing front slinger using a

hammer and a suitable punch or chisel, takecare not to damage propeller shaft.

NOTE:The slinger must be discarded once it is removedand a new one installed on reassembly.

Figure 4C-43

REINSTALL1. Install new front slinger onto front propeller

shaft using a suitable size tube, as shown.NOTE:During this operation, ensure that the ears on thefront end of the propeller shaft (and not the frontyoke) are resting on the press plates.

Figure 4C-442. Install new centre bearing assembly to

propeller shaft using a suitable size tube.

Figure 4C-45

3. Install new rear slinger using a suitable sizetube.

Figure 4C-46NOTE:If the rear slinger is installed on too far, the slingerand centre bearing cup will rub.The slinger is correctly installed when in theposition as shown.4. Install bearing upper and lower cup guides to

centre bearing.5. Install spacer/s, if previously fitted and

retaining bolts and nuts to the centre bearingcarrier and tighten to the correct torquespecification.

CENTRE BEARING CUP GUIDE TOCARRIER BOLTS AND NUTS 20 - 25 Nm

TORQUE SPECIFICATION

6. Reinstall constant velocity joint. Refer to2.3 CONSTANT VELOCITY in this Section.

7. Reinstall the propeller shaft. Refer to2.1 PROPELLER SHAFT in this Section.

8. Check propeller shaft phasing. Refer to2.6 CHECKING PROPELLER SHAFTPHASING in this Section.

Figure 4C-47

2.6 CHECKING DRIVELINE ANGLES

MEASURING PROCEDUREThe following procedure is used for investigatingdriveline related vibrations in VT Series modelsfitted with the 4L60-E automatic transmission,where incorrect driveline angles are suspected.NOTE:This procedure is not suitable for measuring angleson drivelines fitted to manual transmission models,as there is no needle roller bearing, front universaljoint, from which to take angular readings.The following checks should be conducted beforecarrying out the driveline angles measuringprocedure:Inspect all universal joints and centre bearing forwear; i.e. dust seals broken, retaining snap ringsbroken or any movement in the universal joints orcentre bearing.Check engine and transmission mountings andtightness of all bolts.Check that the centre bearing spacers (wherefitted) are in place and in the correct location. Referto Figure 4C-1 for details.Check condition of all rear suspension control armbushes and tightness of attachments.The next illustration shows the driveline angles thatneed to be measured.

Figure 4C-481. Place vehicle over a pit or on a four post ‘drive

on' hoist. Leave transmission in neutral, parkbrake off and chock front wheels.

NOTE:It is important that the vehicle's weight is on all fourwheels.2. Ensure vehicle is at kerb weight, i.e. fuel tank

full, without driver, passengers or luggage etc.3. Bounce rear of vehicle up and down to ensure

suspension has settled.5. Remove chocks and push vehicle backwards

or forwards until pinion flange rear universaljoint bearing caps are vertical.

Chock wheels to prevent further vehiclemovement. Before carrying out rest of themeasuring procedure, note the followingpoints;a. At no stage is the vehicle to be moved by

twisting the propeller shaft.b. Ensure that all inclinometer readings are

taken from the right hand side of thevehicle.

c. Mark all universal joint caps thatmeasurements are taken from so thatlater measurements can be taken fromthe same caps.

d. Ensure that universal joint caps are cleanand free from paint and dirt.

e. Ensure that the magnet on theinclinometer sits squarely on theuniversal joint caps.

NOTE 1:For vehicles fitted with the V6 engine, removal ofthe engine pipes and catalytic converter will berequired to gain access to the front universal joint.refer to Section 8B EXHAUST SYSTEM for thenecessary procedure.NOTE 2:Ensure that the inclinometer is positioned and readat each location with the 30 degrees (or 50 degreesif inclinometer is fitted with AU415 scale conversionkit) end of scale facing toward front of vehicle.6. Install inclinometer, Tool No. J23498-A on

pinion flange rear universal joint bearing cap.Centralise bubble and record reading - this isPOSITION 1.

Figure 4C-497. Remove inclinometer, remove chocks and

push vehicle until propeller shaft frontuniversal joint yoke bearing cap is vertical. Re-chock wheels.

8. Install inclinometer on front universal jointyoke bearing cap. Centralise bubble andrecord reading - this is POSITION 2.

Figure 4C-50

9. Remove inclinometer and chocks and rollvehicle to rotate propeller shaft until bearingcaps in propeller shaft rear universal joint arevertical.

10. Chock wheels and place inclinometer on rearuniversal joint bearing cap. Centralise bubbleand record reading - this is POSITION 3.

Figure 4C-5111. Remove inclinometer, remove chocks and

push vehicle until the propeller shaft frontuniversal joint bearing caps are vertical. Re-chock wheels.

12. Install inclinometer on propeller shaft frontuniversal joint bearing cap. Centralise bubbleand record reading - this is POSITION 4.

Figure 4C-5213. To calculate the driveline angles, refer to

Figure 4C-54 and use the following equations;

ANGLE A = POSITION 2 (step 8)less POSITION 4 (step 12).

ANGLE B = POSITION 4 (step 12)less POSITION 3 (step 10).

ANGLE C = POSITION 3 (step 10)less POSITION 1 (step 6).

Refer to 3, SPECIFICATIONS in this Sectionfor nominal angles A, B and C.

Figure 4C-53

DRIVELINE ANGLE EVALUATIONTo determine if a driveline angle is positive ornegative, refer to Figure 4C-55 and the followingexplanation.Determine whether the ‘output’ centreline of theangle being considered, is either above of belowthe ‘input’ centreline.If the output centreline is above the input, then theangle is considered positive. Alternatively, if theoutput centreline is below the ‘input’ centreline,then the angle is considered negative.Examples:Angle A: If the centreline through the frontpropeller shaft is below that of the transmissionoutput shaft, then the angle will be negative, asshown.Angle B: With the centreline through the rearpropeller shaft being above the centreline of thefront propeller shaft, the driveline angle in thissituation will be positive.Angle C: As the ‘output’ centreline through the finaldrive pinion in the example shown, is above thecentreline of the rear propeller shaft section, theangle again, will be positive.

Figure 4C-54Driveline Angles Within SpecificationIf all angles are within specification and a vibrationcondition exists at 20 - 30 km/h, then it may becaused by one universal joint axis having a higherrotational torque than the other. This can only beevaluated after the propeller shaft has beenremoved from the vehicle and each universal jointrotational 'drag' evaluated.1. Remove the propeller shaft assembly. Refer to

2.1 PROPELLER SHAFT in this Section.2. Carefully move each universal joint through

each axis, to assess whether one cross ismore stiff than the other.

Should a higher rotational torque be determined inone of the universal joints, then the followingprocedure is recommended for all of the universaljoint bearing cups:

3. Support yoke 'A' in the palm of one hand, tominimise the possibility of the needle rollersbeing brinelled.

NOTE:Yoke 'A' in the rear universal joint is the pinionflange component, while in the front universal joint,yoke 'A' will be the slip joint.4. Strike the forged part of yoke 'B' with a

hammer, to ensure that the snap ring is fullyseated. Take care not to strike the propellershaft tubing or any machined surfaces duringthis process. With V8 and manualtransmission, take particular care that thespeed sensor toothed ring is not damaged inany way during this process.

5. Repeat seating procedure with the oppositecup.

6. Reverse the position of yokes 'A' and 'B' andrepeat the seating process described in steps2 and 3.

7. Check that the rotational torque required foreach of the two pivot axes is now similar.

8. Should a check of the other universal jointindicate that uneven rotation torque is evident,then the procedure just described should alsobe applied to the cups in that universal joint.

Figure 4C-55

9. Reinstall the propeller shaft assembly, asdescribed in 2.1 PROPELLER SHAFT, thenroad test the vehicle to ensure that thevibration condition has now been corrected.

Driveline Angles Outside SpecificationNOTE:The maximum allowable tolerance fromspecification is ± 0.5°.If driveline angles are not to specification, start byraising or lowering the centre bearing relative to theunderbody by adding, repositioning or subtractingspacers between the centre bearing carrier andunderbody or between the centre bearing carrierand centre bearing.Raising the centre bearing by 7 mm will increaseAngle "A" (or make more positive) by +0.7°, andincrease Angle "C" (or make more positive) by+0.6°.NOTE:Achievement of correct angle "B" (at constantvelocity joint) is not as critical as Angles "A" and"C" for minimising noise and vibration.When driveline angles are to specification, removeinclinometer and reinstall the exhaust system.Refer to Section 8B EXHAUST SYSTEM fordetails.

SYMPTOMS AND CAUSES OF DRIVELINE ANGLE RELATED PROBLEMS1. Initial Acceleration Shudder - A pronounced shudder that occurs during forward acceleration could be

caused by an excessive angle "A".2. Acceleration Delayed Shudder - A vehicle may accelerate smoothly from standstill yet begin to shudder from

15 - 40 km/h. This condition is usually worse when the vehicle is heavily laden and can be caused by aninsufficient angle "C".

3. Boom or Rumble - Vehicles with an excessive angle "C" may suffer from cabin boom or rumble from 40 km/hon overrun/coast. Condition is usually worse when vehicle has a minimal load in the rear. Acceleration inreverse with an excessive angle "C" will cause severe driveline vibration.

2.7 CHECKING PROPELLER SHAFT PHASINGBefore attempting to diagnose propeller shaftphasing induced vibrations check the following:1. It is essential that driveline angles are set to

specification, refer to 2.6 CHECKINGDRIVELINE ANGLES in this Section.

2. Check that rear axle pinion flange andpropeller shaft rear universal joint flangealigning marks are aligned as close aspossible.

3. Check that all propeller shaft assemblyattaching bolts and nuts are tightened to thecorrect torque.

4. Road test vehicle and check for the followingsymptoms:a. "RUMBLE" noise and vibration

throughout vehicle speed range, usuallyworse during "float" or "overrun"conditions.

b. At higher speeds, a "BEAT" may develop.NOTE:A rumble is a constant sound, e.g. 'the rumble ofdistant thunder', whereas a beat is a low frequencycycling of the rumble noise.If the vehicle exhibits any of the symptoms noted instep 4, the next step is to measure the propellershaft phase angle, using the inclinometer, Tool No.J23498-A.NOTE:As the phase angle specification does not exceed37 degrees, use of the conversion scale AU415 isnot required for VT Series vehicles.1. Place vehicle over a pit or on a four post 'drive

on hoist'. Leave transmission in neutral andpark brake off. Vehicle weight must be on allfour wheels.

2. Disconnect exhaust system from rear ofcatalytic converter (V6) or converters (V6Supercharged or V8). Discard gaskets on theV6 Supercharged/V8 flanges.

NOTE:Only one flange of the V6 Supercharged/V8 systemis shown.

Figure 4C-56

4. Remove the two retainers from the top postsand discard. Disconnect exhaust systemsupport rings from rear hanger of the rearmuffler. Both V6 and V8 arrangements are thesame.

Figure 4C-575. Remove muffler support to rear crossmember

retainers (2 places - V6, 4 places-V6Supercharged and V8) and discard.

6. Lift up intermediate section of exhaust systemand remove supports from muffler andcrossmember hangers. Then removeintermediate and rear sections of exhaustsystem from beneath vehicle.

Figure 4C-587. Push vehicle backwards or forwards until

propeller shaft front universal joint yokebearing caps are vertical, refer to Figure 4C-60.

Figure 4C-59

8. Place inclinometer on propeller shaft frontuniversal joint bearing cap with scale facingtoward front of vehicle. Chock rear wheels toprevent vehicle movement.

9. Move inclinometer arm to centralise bubbleand note reading.

Figure 4C-6010. Remove inclinometer from front universal joint

bearing cap and install onto propeller shaftrear universal joint bearing cap.

11. Move inclinometer arm to centralise bubbleand note reading.

12. Subtract this reading from the reading taken instep 5 to give propeller shaft phase angle.

PROPELLER SHAFT PHASEANGLE SPECIFICATION 0.0 ° ± 7.5 °

NOTE: A positive phase angle indicates that the rearuniversal joint leads the front, whereas a negativeangle is the reverse situation. Refer toFigure 4C-63 for further information on positiveand negative phase angles.13. If phase angle is to specification, remove the

inclinometer and install exhaust system asfollows:a. With V6 Supercharged or V8 engined

vehicles, ensure the catalytic converterflange is clean and free from any gasketmaterial. With V6 engined vehicles, checkthat the catalytic converter to intermediateexhaust pipe bolts springs and sealingring are all in a serviceable condition.

Figure 4C-61

b. Reinstall exhaust system, using a newgasket (V6 Supercharged/V8 enginedvehicles) at the catalytic converter andnew hanger retainers for the mufflersupport to rear crossmember. Tightenintermediate exhaust pipe to converterattaching bolts to the correct torquespecification.

INTERMEDIATE EXHAUST PIPETO CATALYTIC CONVERTER All Engines:

BOLT TORQUE SPECIFICATION 40 - 50 Nm

c. Check exhaust clearances as detailed in Section 8B EXHAUST SYSTEM.

PHASE ANGLE EVALUATIONTo determine if a propeller shaft has a negative,positive zero phase angle, refer to Figure 4C-63and the following explanation:Zero phase angle: This condition applies when thecentreline running through the front universal jointyoke of the propeller shaft, is in line with thecentreline of the rear propeller shaft yoke.Positive phase angle: If it is determined that therear propeller shaft yoke is leading the front yoke(when rotating in a forward direction), then this isreferred to as being a positive phase angle.Negative phase angle: Here, the reverse applies.Should the rear universal joint ‘trail’ the front, thenthe phase angle is negative.

Figure 4C-62If the propeller shaft phase angle is different thanthe specification, refer to the following tables todetermine the appropriate action.

PHASE ANGLE EVALUATIONPHASEANGLE

(Degrees)

from−7.5 to −15and below

from−7.5 to +7.5

from+7.5 to +15and above

ACTION Re-phaseSee next

None(Standard)

Re-phaseSee next

Re-phasing Propeller ShaftNOTE:Once the propeller shaft phase angle has beencorrected, the assembly must be re-balanced.1. Remove constant velocity joint, as detailed in

2.4 CONSTANT VELOCITY JOINT in thisSection.

2. Remove and replace centre bearingassembly, as detailed in 2.5 CENTRE BEARING in this Section.

3. Reinstall constant velocity joint as detailed in 2.4 CONSTANT VELOCITY JOINT in thisSection.

NOTE:To correct an excessive phase angle, install theconstant velocity joint around one spline. Whichdirection, will be determined by the phase anglereading.4. Re-balance propeller shaft.5. Reinstall propeller shaft. Refer to

2.1 PROPELLER SHAFT in this Section.

3. SPECIFICATIONSPROPELLER SHAFT IDENTIFICATION

ENGINE TYPE TRANSMISSION TYPE

BODY STYLE PROPELLER SHAFTPRODUCTION I.D.

MANUAL SEDAN JDV6 STATION

WAGONJF

AUTOMATIC SEDAN JGSTATIONWAGON

JH

V6 Supercharged AUTOMATIC SEDAN JGMANUAL SEDAN MK

V8 STATIONWAGON

ML

AUTOMATIC SEDAN JJSTATIONWAGON

JK

Figure 4C-63DRIVE LINE ANGLES - VEHICLE AT CURB WEIGHT

ALL VT SERIES VEHICLES

Transmission Driveline Angle “A” Driveline Angle “B” Driveline Angle “C”

Automatic + 0.0° ± 0.5° Greater than ± 1.0° 0.0° ± 0.5°

Figure 4C-64

PROPELLER SHAFT:Phase Angle: Zero ± 7.5°Balance Specification 10 g cm @ 3,000 r.p.m., on turn over. Low spot

of propeller shaft is marked on the rear universaljoint flange with a daub of paint.

Maximum Rotational Runout 0.25 mmThis can only be measured accurately on a suitableshaft jig, where the propeller shaft assembly iscorrectly supported at the front, centre and rear.

LUBRICANT:Front and Rear Universal Joints Lithium soap grease to Holden's Specification HN1147Constant Velocity Joint Molybdenum Disulphide grease to

Holden's Specification HN1583V6 Manual Transmission Output Shaft Spigot Molybdenum Disulphide grease to

Holden's Specification HN1271SEALANT:

Loctite 510 High Temperature GasketEliminator(or equivalent) To meet Holden's Specification HN1593Loctite 242 Thread Sealant (or equivalent) To meet Holden's Specification HN1256, Class 2, Type 2

4. TORQUE WRENCH SPECIFICATIONSNm

Propeller shaft rear universal joint flange to pinionflange bolt

55 - 65

Centre bearing carrier to underbody reinforcement bolt 20 - 35Flexible coupling bolt (All manual transmission) 74 - 80Engine rear crossmember to side frame bolt (V8 withmanual transmission)

50 - 65

Constant velocity joint to rear propeller shaft screw 35 - 40Centre bearing cup guide to carrier bolts and nuts 20 - 25Exhaust pipe to engine manifold (V6 engine) 18 - 35Exhaust pipe to catalytic converter attaching bolt (Allengines)

40 - 50

Speed sensor bracket bolt to manual transmission (V8engine)

15 - 20

5. SPECIAL TOOLS

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

J23498-A INCLINOMETER PREVIOUSLY RELEASEDFOR "V" CAR.

J22912-01 PRESS PLATES PREVIOUSLY RELEASEDFOR TORQUEMASTER AND

FIVE SPEEDTRANSMISSIONS.