SVE BULLETIN E-Series Wheelbase Modification Driveline Noise Reduction

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1 Q-238 SVE BULLETIN SPECIAL VEHICLE ENGINEERING BODY BUILDERS ADVISORY SERVICE via Website: (click "Contact Us") Toll-free: (877) QVM Bulletin: Q-238 Date: 03 December, E-Series Wheelbase Modification Driveline Noise Reduction Models Affected: 2016 E450 Cutaway (Motorhome Prep Package) and E450 Stripped Chassis w/ 6.8L gas engines with wheelbase stretches for motorhome applications. Description: Some 2016 E450 cutaway and stripped chassis with wheelbase modifications equipped with 6.8L engine /6R140 transmission powertrains may exhibit a vibration and moan at 55MPH to 65MPH under load. Center Bearing Bracket #1 Center Bearing Bracket #2 6R Transmission Coupling Shaft #1 Coupling Shaft #2 Driveshaft Differential U-Joint 1 U-Joint 2 U-Joint 3 U-Joint 4 Internal Radial Damper Location Figure 1: Modified Driveline Overview Note: Due to the varying design of second unit bodies / content / cross member location, results may vary. 1. Recommendations for Vehicles with a Final Wheelbase of 223 : Primary Recommendation 1. Utilize a 3 piece driveshaft with outside diameters of 3.5, 3.5, and 3.5 outboard slip (See Table 3). 2. Press Internal Radial Damper (IRD) in the coupling shaft #2 (CS2) 10 toward front of vehicle from Center Bearing #2 (CB2) Weld Yoke. (Refer to IRD Location image in Figure 2 below) Document: SVE Bulletin No. Q-238 Page 1 of 7

2 3. Rebalance IRD drive shafts and align yellow dots (light side to high side alignment) properly prior to installation. 4. Pinion angle can be adjusted using a 2 degree wedge / shim (Ford service part number AC3Z-5A313-A). New E-450 U-bolts (YC2Z-5705-AA) and nuts (W S441) will be required after pinion angle is adjusted. The wedge has FRONT indicator stamped into the face - place this wedge so that the thick end is at the front of the vehicle (opposite the indicator stamp on the face. See Appendix 1 for Wedge and U- bolt install procedure. 5. Adjust center bearing bracket heights to yield working angles seen in the Optimized Driveline Angles for 3 Piece Driveshaft table. Secondary Recommendation 1. Utilize a 3 piece driveshaft with outside diameters of 3, 3, and 3 outboard slip. 2. Adopt stiffened Center Bearing #2 (CB2 see figure 3) bracket and adjust height to optimize angles. 6. Pinion angle can be adjusted using a 2 degree wedge / shim (Ford service part number AC3Z-5A313-A). New E-450 U-bolts (YC2Z-5705-AA) and nuts (W S441) will be required after pinion angle is adjusted. The wedge has FRONT indicator stamped into the face - place this wedge so that the thick end is at the front of the vehicle (opposite the indicator stamp on the face. See Appendix 1 for Wedge and U- bolt install procedure. 3. Adjust center bearing bracket heights to yield working angles seen in Table 1: Optimized Driveline Angles for 3 Piece Driveshaft. Table 1: Optimized Driveline Angles for 3 PC Driveshaft U-Joint Positon Optimized Working Angles (+/- 0.3) Min Min. Internal Radial Damper Location and Stiffened Center Bearing Bracket inches toward front of vehicle from Center Bearing #2 Weld Yoke Figure 2: Internal Radial Damper Location Document: SVE Bulletin No. Q-238 Page 2 of 7

3 Table 2: Recommended Parts List Figure 3: Example of Stiffened Center Bearing Bracket Part Part number Description Quantity per Vehicle Internal Radial Damper AC2Z-4A263-A Tube Assembly - Drive 1 Shaft Internal Damper U Bolt E-450 YC2Z-5705-AA U Bolt E-450 RR Spring 4 U Bolt Nuts W S441 Nut M16 HF PTM Degree Axle Wedge AC3Z-5A313-A Wedge RR AX SPG ST 2 Table 3: 3.5 OD Coupling Shaft Dimensions Outside Diameter Wall Thickness Inside Diameter Inch mm Inch mm Inch mm Recommendations for Vehicles with a Final Wheelbase Less Than 223 : Motorhomes with 3 Piece Driveshaft (utilize instructions from section 1) 1. Adopt optimized driveline angles as shown in the Optimized Driveline Angles for 3 PC Driveshaft table 1 along with a stiffened CB2 bracket 2. If step 1 is not sufficient, adopt production IRD in addition to step 1 3. If step 2 is not sufficient, additional IRD tunings may be needed and will have to be developed between upfitters and suppliers Motorhomes with 2 PC Driveshaft (utilize instructions from section 1) 1. Adopt optimized driveline angles from the Optimized Driveline Angles for 2 PC Driveshaft table 4 in addition to stiffening CB bracket 2. If step 1 is not sufficient, adopt production IRD in addition to step 1 3. If step 2 is not sufficient, additional IRD tunings may be needed and will have to be developed between upfitters and suppliers Document: SVE Bulletin No. Q-238 Page 3 of 7

4 Table 4: Optimized Driveline Angles for 2 PC Driveshaft U-Joint Positon Optimized Working Angles (+/- 0.3) 0.5 Min How to Measure Driveline U Joint Angles 1. Level/Zero out Angle Master a. This should be done on the stretched portion of the frame (Figure 4). b. Ensure Angle Master is zeroed prior to measuring U joint angles c. Angle Master must maintain lateral orientation throughout all measurements. (i.e. display must always be read on driver s side throughout all measurements) Figure 4 2. U-Joint #1 - Transmission Measurement (Figures 5 and 6) Place angle master on side of 23 Stamp Ensure that the angle master is flush on the surface next to the 23 stamp, not over it. Figure 5 Figure 6 Document: SVE Bulletin No. Q-238 Page 4 of 7

5 3. U-Joints #2 & #3 Coupling Shaft #1 (CS1), Coupling Shaft #2 (CS2), and Drive Shaft (DS) Measurement 4. Joint #4 Pinion Measurement Place angle master on Bottom of Driveshaft. Ensure the angle master follows the Contours of Driveshaft Figure 7 Lay angle master vertically on flange. Driveshaft may need to be adjusted prior to measurement to ensure it is perpendicular to the frame. Figure 8 Figure 9 Document: SVE Bulletin No. Q-238 Page 5 of 7

6 Appendix 1: Pinion Angle Adjustment Instructions 1. Support the axle. 2. Remove and discard the 4 nuts and 2 U-bolts to allow the rear axle to separate from the rear spring. 3. Insert the wedge between the rear spring and the spring seat placing the thick end of the wedge at the front of the vehicle (opposite the FRONT indicator stamped in the wedge face). Position the wedge so the center bolt through the spring leaves passes through the wedge hole. The spring center bolt will protrude through the wedge and needs to be aligned with the hole in the axle seat to ensure proper seating of the spring onto the axle seat face. 4. Install 2 new U-bolts and 4 new nuts. With the vehicle at curb height, tighten the U-bolt nuts evenly in an X-type pattern in 5 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 100 Nm (74 lb-ft). Stage 3: Tighten to 150 Nm (111 lb-ft). Stage 4: Tighten to 200 Nm (148 lb-ft). Document: SVE Bulletin No. Q-238 Page 6 of 7

7 5. Repeat steps 1 through 4 on the opposite side of the axle. 6. Remove the support from the axle. Copyright 2015 Ford Motor Company Document: SVE Bulletin No. Q-238 Page 7 of 7

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