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Potential Damage:
Catastrophic damage to transmission housing, transfer box and exhaust system. Damage is speed dependent, the greater the
rotational speed of the prop shaft at failure, the more significant the damage under the vehicle.
Cause:
Factory installed U-joints in front prop shaft lack grease ports. Because the trunnions caps/bushings of the spider (also know as a
“cross”) cannot be greased, they will eventually dry out, corrode and loose ability to function. Consequently, the spider will overheat
and break, thus leaving only one end of the prop shaft supported. The loose end will whip around under the vehicle damaging
everything in its path.
Precision brand
Spider Cap locates port
here.
Option 1: Neapco 1-0005, Grease point is located axially with one of the 4 trunnions (legs that make the X shape). Pictured above w/
box from Advanced Auto. If you ask for a Rover replacement, they won’t have it. You must request part for a 1993 Volvo 240.
Option2: Precision 344, grease fitting is located between two adjacent trunnions of the spider.
Option 1: Precision 617 Replacement Ball Kit pictured below. This one from www.rockauto.com.
Option 3: NAPA PUJ617 Double Cardan (CV) Ball Seat Repair Kit (I can’t be certain if this includes the ball, b/c I have not seen the
actual product)
Tools
1. Snap ring tool
2. U-joint tool (rent from Advance Auto, requires deposit, free after returning tool)
3. Slide hammer (rented from Autozone, requires deposit, free after returning tool)
4. Hammer (ball peen). Don’t use a claw hammer; it may fragment if it fractures.
Service Notes:
There are 3 spiders on the front drive shaft, front (nearest the front axle), middle and rear. The middle and rear spiders are part of
the double Cardan which bolts to the transfer box. Located on the prop shaft, there is a grease fitting plug (tapered set screw). It is
the grease port for lubricating the slip yoke. When you remove your front spider, retain the original grease fitting from the spider so
you can use it to grease the slip yoke. I think It is a metric size grease fitting.
1. Before you remove the shaft, mark the orientation of prop shaft relative to the transfer box and front differential, I used liquid
paper, be careful it doesn’t wear off.
2. Reverse the position of the tool to press the spider back into the yoke to remove the opposite cap.
3. Repeat the process to other to ends of the spider.
4. Clean yoke and flange, this is important. If the grooves the C clips sit in are not clean, you’ll have difficulty fitting the new
clips. I used a brass wire brush and brake cleaner to get it clean.
5. Carefully remove all 4 caps from new spider and set aside.
Spider
Trunnion
Receiving
hole
NOTES:
The front end of the shaft is connected by four 3/8” 24 TPI bolts.
Throw away old nuts and use new ones that are equal in grade and NEVER greater in grade than the bolt. Nuts are designed to
yield (deform) around the threads of a bolt, thus distributing the load evenly among the nut threads. This strengthens the nuts due to
the cold work that takes place. Source: Shigley and Mischke, Mechanical Engineering Design 4th Edition, 1989.