DIY Network

1962 Ford T-Bird: Driveshaft and U-Joint From "Classic Car Restoration" episode DCR-303

Auto-restoration expert Keller Wallace offers advice on diagnosing and repairing driveshaft problems.

With the leaf springs refurbished and the old shocks replaced with new ones, the T-bird's suspension and ride should be much improved. In this segment, Steve Magnante is joined by auto-restoration expert Keller Wallace as work begins on the driveshaft and rear universal joint.

Materials:

Standard automotive tools (socket wrenches, extensions, combination wrenches, screwdrivers, nut-drivers, etc.)
Air compressor and impact wrenches (optional)
Mallet or hammer
Replacement universal joint (i.e., "U-joint")
Needle-nose pliers
Bench vise
Jack and jack-stands
Floor jack
Spray lubricant

Safety Equipment:

Work gloves
Safety glasses or other eye protection

Safety Alert: Always wear eye protection when working with power tools or pneumatic tools.

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	Figure A
	Figure B
	Figure C

Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Driveshaft and U-Joint

According to restoration expert Keller Wallace, symptoms arising from a bad driveshaft include vibration in the chassis -- as opposed to the more common problem of vibration in the steering wheel. There can also be a "clunking" sound or shudder when the car is shifted from neutral into drive.

Typically what fails with respect to the driveshaft are the small needle-bearings inside the universal joint (figure A). Lack of lubrication can cause these bearings to wear out resulting in vibrations or other problems connected with the rear axle. Replacement U-joints are inexpensive and available at most auto centers and auto-parts stores.

• Use a 1/2-inch socket wrench to remove the driveshaft nuts and two U-bolts, then disconnects the rear U-joint from the differential yoke (figure B).

• With the joint free, carefully pull the driveshaft toward the rear of the car and out from the transmission.

• With the driveshaft and U-joint removed from the vehicle, they can be inspected more closely. Our driveshaft appeared to be in fairly good condition, with no obvious dents or damage. The U-joint, however, seemed very tight in its yoke, indicating possible problems.

• With the driveshaft held steady, use needle-nose pliers to carefully remove the retaining clips that hold the bearings in the yoke (figure C).
  
• With the clips removed, and with the joint of the driveshaft held in the vise (figure D), the weld of the yoke can be struck lightly with a hammer to loosen the bearing caps.

  Note: It's important to tap only on the weld area, not on the driveshaft tube, to avoid damaging the driveshaft.

• After a few taps, the caps should be loosened sufficiently so that the U-joint can be taken apart (figure E). If necessary, the last bearing cap can be forced out using a nut-driver.

  Figure D

  Figure E

  
  
• Once removed, the U-joint can be inspected for wear. In our case, the joint exhibited considerable wear, and the decision was made to replace it. The yoke of the driveshaft, however, appeared to be in good shape (figure F). If a yoke is damaged or worn, it can usually be repaired by a professional at a machine shop.

• When installing the new U-joint, first tape the side-caps onto the U-joint (figure G) so that they don't fall out during the installation.

  Figure F

  Figure G

  
  
• Remove the top and bottom caps, and place one of the caps into the yoke-joint.

• Position the new U-joint into the yoke by first placing one of the open ends into the socket -- where the cap was placed -- then placing the other end into the opposite side of the yoke (figure H).

  Tip: When positioning the U-joint into the yoke, make certain that the joint is oriented so that the joint's grease-fitting is toward the driveshaft. If the joint is installed the other way -- toward the yoke -- there won't be sufficient room to access the grease fitting with a grease gun for lubrication.

• Put the last cap in place, and put the U-joint into the vise. Use the vise to slowly apply pressure and squeeze the caps into place, and set the U-joint in the yoke (figure I). As you tighten the vise, continue to work the U-joint in its yoke to ensure that it stays mobile -- or "floating" -- and does not bind.

  Figure H

  Figure I

  
  
• Open the vise, then position a socket that's smaller than the cup to act as an aid for pressing the caps in slightly further. Tighten the vise on the socket until the caps are pushed in far enough that the retaining clips can be installed.

• Using the needle-nosed pliers, install the retaining clip that hold the bearing cup on the universal joint (figure J). Repeat this step for the clip on the opposite side of the joint.

• Use a small wrench to install the grease-fitting onto the U-joint (figure K). Tighten the fitting just enough to snug it; avoid over-tightening which could strip the threads or break the fitting.

  Figure J

  Figure K

  
  

  Figure L

• Remove the tape from the side bearing-caps, and hold them in place as the driveshaft is reinstalled on the vehicle. To reinstall the driveshaft, simply reverse the steps that were used earlier to remove it. Carefully insert the front of the front of the driveshaft into the transmission housing, and bring the rear U-joint up to the differential yoke (figure L).

• Install the two U-bolts that hold the U-joint in the flange, add the lock-washers and nuts and tighten them securely. The U-bolt nuts should be tightened uniformly on both sides to a snug fit -- with about 10 to 15 foot-pounds of torque.
  

RESOURCES :

Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896

Haynes Restoration Manual Classic Car Interior: The Complete Illustrated
Model: 185010932X
Author: Ken Henson

To order this title from Amazon, click here.
Motorbooks International

The Complete Idiot's Guide to Car Care and Repair Illustrated
0028644328
Dan Ramsey
(December 2002)
To order this title from Amazon, click here.
Alpha Books

Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners and Restorers of Classic and Collectible Automobiles
1557881944
Jim Richardson
(November 1994)
To order this title from Amazon, click here.
H.P. Books

T-birds.com
T-Birds.com
A website dedicated to the appreciation of 1961 through 1963 Ford Thunderbirds. Hard-to-find restoration parts and materials, including reconditioned original t-bird body parts, can be found through t-birds.com.

GUESTS :

Keller Wallace
Keller Wallace Street Rods
Volunteer Street Rod Association
Knoxville, TN