Drive Shaft

205-01-1 205-01-1

Section 205-01 Drive Shaft

Applicable Model: Boomday

CONTENTS PAGE
Specifications
Specifications................................................................................................................................. 205-01-2
Descriptions and Operations
Drive Shaft...................................................................................................................................... 205-01-3
Cardan Joints................................................................................................................................. 205-01-3
Diagnosis and Testing
Drive Shaft...................................................................................................................................... 205-01-4
General Procedures
Inspection of Cardan Joint Cross................................................................................................... 205-01-5
Drive Shaft Beating........................................................................................................................ 205-01-6
Inspection of Drive Shaft Spline Backlash...................................................................................... 205-01-7
Removal and Installation
Drive Shaft - Front.......................................................................................................................... 205-01-8
Drive Shaft - Rear........................................................................................................................... 205-01-9
Disassembly and Assembly
Sliding Fork of Drive Shaft............................................................................................................ 205-01-11
Cardan Joints............................................................................................................................... 205-01-13

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Specifications

Material Specifications

Name Specification
Lubricant -

Component Specifications

Name Specification
Diameter of cardan Joint cross pin 16.90 ~ 17 mm
Drive shaft beating
Standard Value 0.3 mm
Limit Value 0.5mm
Spline sliding clearance of drive shaft
Standard Value 0.06 ~ 0.14 mm
Limit Value 0.3 mm

Torque Specifications

Name Nm
Set bolt for drive shaft flange and drive gear flange (167 mm) 36 ± 3
Set bolt for drive shaft flange and drive gear flange (194 mm) 64 ± 4
Set bolt for central shaft of drive shaft 62 ± 12
Lock nut for flange 120 ± 10

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Descriptions and Operations

Drive shaft
 TTENTION: Inspect cardan joint oil seal
A
for cracks or leaks when lifting a vehicle
to lifting frame. Replace the cardan joint if
necessary.
The change of drive shaft accommodate to
the length of power train. Drive shaft transmits
power the front and rear axles. Drive shaft is
composed of cardan joint, connection shaft and
bushing fork. All drive system shafts are subject
to balance adjustment.
Cardan joint
Cardan joint connects with drive shaft and
enables the up-and-down movement of drive
shaft.

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Diagnosis and Testing

Drive Shaft
Refer to section 205-00.

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General Procedures

Inspection of Cardan Joint Cross

1. C
 ardan joint cross pin outer diameter R:
Standard value: 17 mm.
Limit value: 16.90 mm.

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General Procedures

Drive Shaft Beating

1. S upport both ends of drive shaft with V
Type block, to inspect shaft center with a
dial indicator probe. If measured beating
value exceeds the standard value, to amend
it with bench press or replace with a new
shaft.
Standard value: 0.3 mm.
Limit value: 0.5 mm.

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General Procedures

Inspection of Drive Shaft Spline Clearance

1. Inspect the backlash clearance L between
spline sleeve cardan joint yokes and drive
shaft spline.
Standard value: 0.06 ~ 0.14 mm.
Limit value: 0.3 mm.

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Removal and Installation

Drive Shaft - Front

Removal and Installation 194 mm fixing torque: 64 ± 4 Nm.

1. Place transmission in free position, park the

vehicle on a lifting,refer to section 100-02
for more information.
2. Mark the front flange and drive gear flanch.
● Mark rear flange and transfer case flange.

5. Remove front drive shaft.

3. Remove 4 bolts fixing rear flange to transfer case.

6.  ATTENTION: If new bolts which fix drive

shaft to axle and drive shaft to transfer case
are not available, apply sealant at threads of
formal bolts.
For installation, reverse the removal
procedures
4. Remove 4 bolts fixing front flange to drive
gear flanch.
167 mm fixing torque: 36 ± 3 Nm.

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Removal and Installation

Drive Shaft – Rear

Removal and Installation ● Fixing torque: 62 ± 12 Nm.

1. S
 et transmission at free position, park the
vehicle on a lifting, refer to section 100-02
for more information.
2. M
 ark drive shaft flange and rear axle drive
gear flanch.

5. Remove and abandon 4 drive shaft bolts.

3. M
 ark drive shaft sliding fork and transm-
ission or transfer case expansion shell.

6.  ATTENTION: Do not rotate drive shaft

when removing up-and-down slide fork from
transmissionoutput shaft.
Rotate drive shaft after assembly.

4. R
 emove 2 bolts of drive shaft center bearing.
● Abandon drive shaft center bearing bolts.

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Removal and Installation

7.   TTENTION: Apply sealant to the original

A
bolt threads.
 TTENTION: Fit drive shaft flange tightly
A
to flanch guider of rear axle drive gear.
Ensure drive shaft falls to drive gear flanch
squarely, fasten bolts evenly in accordance
with the order of cross-tightening.
 TTENTION: Make sure all aligned with the
A
mark.
For installation, reverse the removal
procedures.

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Disassembly and Assembly

Sliding Fork Drive Shaft Sleeve

Diagram of drive shaft sliding fork parts 2. Mark the position of drive shaft and central
bearing for assembly alignment.

Item Description
3. D isconnect the connection of flange to
1 Bolt (4 pcs) drive shaft.
2 Spring washer
3 Lock nut
4 Flange
5 Bearing Components

General Tools

Drawing devices

Material Specifications

Item Specification
4. Remove and abandon lock nut.
Lubricant -

Disassembly
1. D
 isassemble rear drive shaft, refer to
the section of Drive Shaft Removal and
Installation for more information.

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Disassembly and Assembly

5. Disassemble flange. Fixing torque: 120 ± 10 Nm.

General tools: drawing devices.

4. Push the outer edge of flange bolt to shaft

groove for retaining nut.
Installation
1. Clean up bearing installation and connection
surfaces, and fill with lubricant.

5. Connect and fasten flange and drive shaft.

● Aligned with the marks for correct installation.

2. Mounting Flange. 6. D isassemble rear drive shaft, refer to

the section of Drive Shaft Removal and
● Aligned with the marks for correct installation. Installation for more information.

3. Install a new lock nut.

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Disassembly and Assembly

Cardan Joint
Cardan Joint Parts Illustration 3. When tapping the collar rafter, the needle
bearing that gradually exposes can be
removed by hand.

Item Description
1 Retaining Ring 4. Remove cross shaft and flange rafter.
2 Needle Bearings 5. Remove butter mouth.
3 Oil seal
Assembly
4 Flange Yoke
1. Assemble butter mouth.
5 Butter Mouth
6 Cardan Joint Cross 2. Assemble needle bearing.
1. Apply molybdenum disulfide grease to oil
Disassembly seal lip and needle bearings.
1. D
 isassemble retaining ring. 2. Fit the cross to flange rafter, pack needle
bearing in flange rafter under the guidance
2. T
 ap the collar rafter with a wooden or cop-
of cross.
per hand hammer to push out bearing by
vibration.

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Disassembly and Assembly

3. Pad a wooden block to needle bearing at

assembly.

3. Assemble retaining ring.

After fixing inner hexagon wrench in place, fix
a retaining ring with appropriate thickness to
ensure that cardan joint cross pin backlash is
less than 0.1mm.
Select a thickest retaining ring that can be fit it
in the groove of another end.

Ring Thickness (mm) Identification Color

1.5 Blue
1.545 White
1.59 Yellow
1.635 Green
1.68 Colorless

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