6 Ways Your U Joint Will Fail

Oh, if only we lived in a world where mechanical parts never broke! Sadly, in reality, a faulty universal joint can wreak havoc on your applications.

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Top 6 Indicators That Your U Joint is Failing

In the practical world of manufacturing, we know all too well that components can and do fail, particularly if they're not chosen or applied correctly. This article aims to shed light on the primary failure modes of universal joints, and how to rectify these issues. Let's delve into the most common signs of a failing u joint.

1. Excessive Torque

If your setup imposes too much torque on a universal joint, failure is almost inevitable. This may manifest as a shearing of the yoke ears or pin failure. In joints made from non-hardened stainless steel, excessive torque may result in deformation, causing poor articulation or binding of components, ultimately hindering future operations. Even if the torque doesn't break or deform the joint, it can still accelerate wear, increasing the play and backlash and weakening the components due to material removal.

Solution: If your system seems fine otherwise, you may need a larger universal joint or a different design—like our High Strength or Leveler Strength models—to handle the elevated loads.

2. Excessive Operating Angle

Every universal joint has a maximum operating angle, which decreases as the load and speed increase. An excessive angle might cause 'notchiness' or a lack of smooth operation.

Solution: If you can't reduce the operating angle, consider using a double u-joint to decrease the angle per joint. Sometimes, modifying the torque or RPM can also help accommodate a higher operating angle.

3. Over-Speeding

A universal joint can fail if subjected to excessively high RPMs. The recommended maximum operating speed depends on factors like:

• Bearing configuration (needle bearings handle higher speeds better than friction bearings)
• Applied torque (higher torque necessitates lower speeds)
• Operating angle (higher angles require lower speeds)
• Length of a Double or Telescoping U-Joint assembly
• The type of lubricant used

High friction heat due to high torque and continuous operation can lead to lubrication failure, excessive wear, and joint damage. High angles increase the movement on bearing surfaces, contributing significantly to bearing speed.

Solution: If your u-joint is suffering from excessive RPM, consult your application engineer to verify if the joint design is appropriate. Maybe a needle bearing or composite bearing joint would be better for high-speed, continuous operations. If the angle is too severe, consider a double universal joint to handle high RPMs and angles.

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4. Insufficient Lubrication

Proper lubrication is essential for any bearing surface. If your u-joint is binding or exhibits high wear, a lack of lubrication might be the issue.

Solution: Re-lubrication is an option, particularly if the joint has lubrication fittings. A protective boot can also be fitted to retain lubricant and keep debris away. If a boot isn't feasible, dry film coatings or platings might provide long-term lubrication. Consider a needle bearing design for enclosed, long-term lubrication without the need to add or replace grease.

For more details, visit Differences between single, double and telescopic joints.

5. Improper Installation

A universal joint must be correctly installed to function properly. Misaligned shafts, missing support bearings, or incorrect mating dimensions can all result in malfunction and stress-related failures.

Solution: Belden Universal offers a variety of standard and custom hub configurations for straightforward installation. Our engineers can design a solution tailored to your system's input and output shafts. Engaging Belden early in the design process can help identify the most economical and suitable bore configurations for your needs.

6. Inaccurate Manufacturing

Not all universal joints are of equal quality. Low-cost, offshore joints often come from outdated, imprecise machinery, resulting in wide tolerance bearing surfaces. If your application demands tight tolerances, an offshore product might not be the best choice.

Solution: Belden Universal's products are precision-machined on modern CNC equipment to ensure accurate bearing surfaces and mating features. Our in-house engineering team can craft the exact universal joint needed for your application, cost-effectively.

In summary, if you're facing issues with your universal joint or drive shaft in a demanding application, don't hesitate to contact Belden Universal at 708-578-6997 or Get in Touch. Our skilled application engineers are ready to help you find the perfect u-joint or drive shaft at a competitive price.

When a u-joint fails, it can lead to a vehicle losing control, potentially leaving the driver stranded. Understanding the causes of u-joint failure is thus crucial for safe driving.

Let's examine the most common causes of u-joint failure:

1. Lack Of Grease

This applies to both greaseable and maintenance-free u-joints.

Greaseable U-Joints

Regular greasing of greaseable u-joints keeps them lubricated and functional. However, even well-greased u-joints can fail if moisture infiltrates them, causing them to seize and malfunction.

Maintenance Free U-Joints

Maintenance-free u-joints usually have an internal teflon coating and grease, which helps prevent corrosion and usually lasts for the joint's service life. Yet they can still fail, often due to improper installation or excessive vibration. Ensure that the u-joint caps are correctly installed to prevent failure.

Lack Of Grease Due To Vibration

Unbalanced driveshafts can generate enough vibration to displace the grease, causing the metal components to grind against each other and eventually fail.

Lack Of Grease Due To Excessive Heat

High temperatures can degrade the grease inside a u-joint, reducing its lubrication efficiency and causing the components to wear out faster. This is more likely when the u-joint is close to a heat source like a muffler.

2. Wear And Tear

U-joints naturally wear out over time, especially when subjected to heavy loads like towing or off-roading. High strain can thin the metal components and create cracks, compromising their ability to transfer torque effectively and leading to failure.

Wear And Tear Due To High Loads

U-joints are designed to manage specific loads. Overloading your vehicle puts extra strain on the u-joints, accelerating wear and potentially causing failure.

Wear And Tear Due To Improper Installation

Ensuring proper alignment of caps and cups during installation is crucial for u-joint longevity. Also, ensure that all bolts are torqued to the correct specifications.

3. Steeper Than Ideal Operating Angles

U-joints are designed to handle certain operating angles. Exceeding these angles can cause them to wear out prematurely. Steep angles, often seen in lifted vehicles or incorrectly set pinion angles, can cause excess vibration, damaging the bearings and seals, leading to failure.

When operating angles are steep, excess vibration occurs. Vibration can damage the bearings. It can also damage the seals, which lets water and dirt in, and lets grease out.

Other Less Common Causes Of U-Joint Failure

Additional but rarer causes include:

• Over-torquing
• Extreme use (racing, excessive towing)
• Aggressive off-roading
• Heavily modified engines

Telltale Signs Of U-Joint Failure

Signs of failing u-joints include:

• Clunking noise when the vehicle starts moving
• Clunking noise when shifting between forward and reverse
• Vibrations felt throughout the vehicle
• Transmission or differential fluid leaks

It’s Important To Find Out The Cause Of The U-Joint Failure

If the underlying issue causing the u-joint failure isn't addressed, the new u-joints will also fail. The solution might be as simple as more frequent greasing, or it could involve correcting an unbalanced driveshaft.

U-joint failure can cause the driver to lose control of the vehicle. If you suspect failure, it's important to replace the u-joints immediately.

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