Propshaft Removal No.002

IVR Safety Bulletin - Number 002

The Health and Safety Executive (HSE) recently contacted the Institute of Vehicle Recovery (IVR) to enquire if there is a ‘safe system of work’ for the removal of propshafts, as a technician had been injured when a centre bearing spacer struck him on the head during removal.

Investigations previously carried out by the IVR had highlighted a number of ways to support the propshaft, which is the key factor when disconnecting or removing it.

The IVR recommends;

For disconnection at the roadside

Support the weight of the propshaft using either a rope, ratchet strap or a piece of equipment similar to that shown in the photograph.

Remove the bolts and where possible tighten the support until the propshaft is held tight against the chassis, to minimize any movement during travel. To refit using the ratchet and rope, as in the photograph, simply lower the propshaft until the bolt holes are re-aligned, fit the bolts and tighten. Where a ratchet strap has been used care should be taken not to release the tension until the propshaft weight has been supported and it can be lowered safely to refit the bolts.

Where possible remove a halfshaft in preference to the propshaft.

IMPORTANT - Care should be taken to ensure that where the propshaft is connected at the gearbox or centre bearing by a spline it cannot become disconnected during travel as this can have a catastrophic outcome.

Some propshafts are connected using ‘single use’ bolts. Technicians must be aware of this or seek advice to ensure that they are not refitted after removal.

For disconnection in the workshop

Where only the rear flange of the propshaft needs removing, e.g. to facilitate work on the rear axle, use the guide above.

Where the complete propshaft needs removing additional safety measures need to be in place. The propshaft needs supporting throughout its length and once disconnected should be lowered slowly to a position where it can be safely removed from the gearbox sliding flange.

Support can be achieved in many ways, but the criteria that should be applied must be safety. Where the support is manual then handling techniques must be applied.

Where the support is mechanical then the equipment must be mechanically sound.

Where straps or ropes are used they must be inspected to ensure there is no damage likely to cause a failure of the equipment. It should also be noted that in the workshop manufacturer’s technical instructions should be followed.

Employers and technicians are reminded that whilst this safety bulletin will help them carry out this task more safely the final responsibility lies with the technician at the scene and any final decision on how to perform the task must be as a result of their risk assessment. This bulletin is for guidance only and the IVR cannot be held responsible for the way in which the task is performed.

PLEASE NOTE - Employers and technicians are reminded that whilst this safety bulletin will help them carry out this task more safely the final responsibility lies with the technician at the scene and any final decision on how to perform the task must be as a result of their risk assessment.

This bulletin is for guidance only and the IVR cannot be held responsible for the way in which the task is performed.

For more information about this safety bulletin or any other Health and Safety issue please contact Terry Crampton (CAE), MIMI, FIVR, Training, Assessment and

Quality Management Representative on behalf of IVR (UK) Limited, on

07710 458230.