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TRADE OF HEAVY VEHICLE MECHANIC

PHASE 2

Module 4 Transmission

UNIT: 3 & 4

Drive Shafts and Axles

Module 34 Unit 3 & 4

Drive Shafts & Axles

Table of Contents
1.0 Learning Out o!e...........................................................1 1.1 "e# Learning $oints......................................................1 %.0 Drive Shafts and Universal &oints.....................................% %.1 %.% %.3 %.4 %.%./ 'un tion.......................................................................% (onstru tion................................................................% O)erating $rin i)le......................................................4 $ro)eller*Shaft +i,ration..............................................Divided $ro)eller Shafts and .heir Su))ort.................0nter!ediate $ro)eller*Shaft Su))ort 1earings...........2

3.0 Drive Arrange!ent........................................................10 3.1 3ear*4heel Drive.......................................................10 3.% 5ot h6iss O)en*.#)e Drive.......................................1% 3.3 (onstant +elo it# &oint...............................................13 4.0 (ornering.......................................................................14 -.0 3ear Axle.......................................................................14 /.0 5alf Shafts.....................................................................12.0 Se!i*'loating.................................................................17.0 .hree*8uarter 'loating..................................................12 9.0 'ull# 'loating.................................................................12 10.0 'ront*4heel Drive........................................................%0

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Module 4 Unit 3 & 4

Drive Shafts and Axles

1.0 Learning Outcome


By the end of these units each apprentice will be able to: Remove a drive shaft and change a carrier bearing and universal joint Refit drive shaft aligning flanges State the function and principle of operation of the universal joints, CV joints (constant velocity), carrier bearings and drive shafts of: a) rear wheeled drive truc b) front wheeled drive vehicle using CV joints Remove!refit a constant velocity joint rubber on a light commercial vehicle drive shaft i"e" bench unit) State the function and principle of operation of a fully floating, three#$uarter and semi floating rear a%le &ismantle a fully floating hub assembly, e%amine and report on the condition of the bearings and reassemble the hub and adjust to manufacturer's specifications Report on the condition of the bearings of the hub

1.1 Key Learning Points


Unit 3 Lu,ri ation )ro edure of drive shaft o!)onents (ondition of :oints and gaiters he 6ed Aligning of shaft flanges ;<o6es= 'un tion and )rin i)le of o)eration of (+ and universal :oints on shaft flanges Dis!antle and asse!,l# )ro edures of drive shaft and (+ :oints (ondition of ,earings he 6ed >ffe ts of entrifugal for e and ,alan e on drive shafts 5a?ards @hen @or6ing underneath vehi les

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Module 4 Unit 3 & 4

Drive Shafts and Axles

Unit 4 Safe :a 6ing )ro edureA use of axle stands $rin i)le of o)eration of different t#)es of axle hu,s Dis!antle and o!)onents asse!,ling )ro edure of hu,

1earing t#)es and ad:ust!ent )ro edure of hu, ,earings Method of lu,ri ation of hu, ,earings @hen fitted Use of lo 6ing devi es and he 6ing ,earing ondition Sealing !ethods and he 6ing ondition of seals $re*load on ,earingsA reason for )re*load and !ethod of setting )reload .he relationshi)s ,et@een engine s)eedA gear ratioA @heel dia!eter and vehi le s)eed 3e)ort on the ondition of the ,earings and seals

.0 !ri"e #hafts and Uni"ersal $oints


2.1 Function
.he )ur)ose of the drive shaft and universal :oints is to trans!it the drive fro! the gear,ox to the ,a 6 axle @ith a s!ooth trans!ission of torBue even though the gear,ox and )inion shaft are never in exa t align!ent.

2.2 Construction
.he shaft is a hollo@ tu,ular steel unit @ith a hoo6 :oint at ea h end. .he :oint onsists of t@o u sha)ed C#o6esD @hi h are onne ted at 90E to ea h other ,# a four*legged ross or Cs)iderD. Feedle roller ,earing !a# ,e used to su))ort the s)ider legs in the #o6es.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

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Module 4 Unit 3 & 4

Drive Shafts and Axles

2.3 Operating Principle


4hen universal :oints are used to onne t t@o units ;e.g. gear,ox and ,a 6 axle= the driven shaft does not rotate @ith unifor! velo it# i.e. it does not turn at the sa!e s)eed during ea h )art of a revolution. 0n one revolution the driven shaft is a elerated t@i e and de elerated t@i e. .his effe t ,eing in reases as the angularit# is in reased. .hese velo it# differen es an ,e an elled in the )ro)eller shaft ,# the use of t@o orre tl# aligned :ointsA the a eleration of one ,eing neutralised ,# the de eleration of the se ond. A sliding :oint is used to allo@ the drive shaft to hange its length as it rotatesA to o!)ensate for the s!all ,a 6@ard and for@ard !ove!ent of the rear axle aused ,# the a tion of the sus)ension s#ste!. 0t is si!)l# a s)lined tu,ular )ortion ,uilt onto the for@ard universal :oint and it slides in s)lines on the gear,ox !ainshaft.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

Two universal joints connected in series

2.4 Propeller-Shaft Vi ration


Due to the high s)eeds the drive shaft rea hesA in to) gear its 3.$.M. is the sa!e as the engineA the shaft !ust ,e ,alan ed to avoid vi,ration. 0f vi,rations o ur in the drive shaft it !a# ,e due to @orn or ,ro6en needle rollers in the universal :oint. .his !a# ,e he 6ed ,# turning the drive shaft ,# hand to he 6 for free )la#A a sei?ed :oint !a# not ,e dete ted this @a# so re!oval of the shaft !a# ,e ne essar# for further he 6s. S!all ars and short vans and tru 6s are a,le to use a single )ro)eller shaft @ith a sli)*:oint at the front end @ithout ex)erien ing an# undue vi,ration. 5o@everA @ith vehi les of longer @heel,aseA the longer )ro)eller shaft reBuired @ould tend to sag and under ertain o)erating onditions @ould tend to @hirl and then set u) s#!)atheti resonant vi,rations in the ,od# of the vehi le * that isA ause the ,od# to Cdru!D or vi,rate as the shaft @hirls.

Simple one-piece propeller shaft with one slip-joint and two universal joints

2.! "i#i$e$ Propeller Shafts an$ %heir Support


.@o*)ie e drive*linesA @ith t@o shafts and an inter!ediate su))ort ,earing are generall# used on tru 6s @ith @heel

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Module 4 Unit 3 & 4

Drive Shafts and Axles

,ases fro! 3.4 to 4.7 !A ,ut there is so!e overla) de)ending on the vehi leDs @or6 role.

Two-piece drive-line with single intermediate support bearing .he t@o*)ie e )ro)eller shaft has three universal :ointsA and the )ri!ar# )ro)eller shaft is of the fixed*:oints*and*tu,e* asse!,l# t#)eA ,ut the se ondar# )ro)eller shaft has a sli)* :oint at the su))ort*,earing end to a o!!odate an# elongation due to sus)ension !ove!ent. Usuall# the )ri!ar# shaft is in line @ith the gear,ox !ainshaft axisA ,ut the se ondar# )ro)eller shaft is in lined slightl# so that it interse ts the rear*axle final*drive )inion shaft.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

Three-piece drive-line with two intermediate support bearings 'or vehi les @ith @heel,ases over 4.7 !A a three*)ie e drive*line @ith t@o inter!ediate su))ort ,earings !a# ,e ne essar#. .here are four universal*:ointsA and it an ,e seen that the inter!ediate shaft lies )arallel to the out)ut shaft of the gear,ox. Again onl# the rear )ro)eller shaft in or)orates a sli)*:oint to o!)ensate for shaft length hange.

2.& 'nter(e$iate Propeller-Shaft Support )earings


0nter!ediate )ro)eller*shaft ,earing*and*!ount asse!,lies are )rovided to )osition and su))ort the divided or s)lit )ro)eller shafts. .he su))ort*,earing asse!,lies are of t@o ,asi t#)esG ;i= ;ii= self*aligning ,earing su))ortsA flexi,le*!ounted ,earing su))orts.

Self*aligning inter!ediate*,earing su))orts have !ostl# ,een used on heav#*dut# tru 6s. One t#)e of self*aligning ,earing su))ort is a dou,le*ro@ ,all*,earing @ith a dee)* grooved inner ra e and an internall# se!i ir ular outer ra e H'ig ;a=. 4ith this arrange!entA an# shaft defle tion is a o!!odated ,# the inner ra e and ,alls tilting a,out the fixed outer*ra e s)heri al seat. !i"ided propeller shaft support%bearing assemblies

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Module 4 Unit 3 & 4

Drive Shafts and Axles

Commercial vehicle double-row self-alignment bearing support

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Module 4 Unit 3 & 4

Drive Shafts and Axles

A se ond !ethod of )roviding self*align!ent for the s)lit shafts is a hieved ,# a single*ro@ dee)*grooved ,all*,earing @ith a s)heri al )rofile on the )eri)her# of the outer ra es. .he ,all ra e is then re eived in a steel su))ort ring @hi h has an internal )rofile to !at h the outside of the ,earingH 'ig. ;,=. 0f there is an# !isalign!ent in servi eA relative !ove!ent of the ,earing and the ring an ta6e )la e @ithout i!)osing strains on the ,earing asse!,l#. 1oth arrange!ents dis ussed need to ,e lu,ri ated )eriodi all# and oil*seals are )rovided to retain the grease and 6ee) dirt out of the ,earing tra 6s.

Commercial vehicle single-row self-alignment outer bearing race 'lexi,le*!ounted inter!ediate*,earing su))orts for divided shafts !a# ,e used for ,oth light and heav# vehi les. All these t#)es tend to have a single*ro@ dee)*grooved ,all* ,earing @hi h fits dire tl# over one of the divided shafts and surrounding this ,earing is a ru,,er !e!,er @hi h is en losed in a steel fra!e. .he inter!ediate shafts are then given su))ort ,# ,olting this asse!,l# to the hassis or ,od# shell. .his ru,,er !ounting )rovides a flexi,le su))ort for the ,earing so that a slight tilt of the shaft an ,e a o!!odated. 0n additionA the flexi,le ru,,er a ts as a vi,ration da!)er and isolates an# )ro)eller*shaft vi,rations fro! the ,od# !e!,ers. 'or extra*heav# dut#A a solid ru,,er ring ,lo 6 fitting over a ,earing hu,A !a# ,e usedH'ig. ; =. 0t an ,e seen that the inner ,earing ra e is held in )osition ,# the universal*:oint flange and that the outer ,earing ra e is lo ated ,# a shi!!ed
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Module 4 Unit 3 & 4

Drive Shafts and Axles

sleeve. 3egular lu,ri ation is ne essar# @ith this asse!,l#. Most light*and heav#*dut# inter!ediate*,earing asse!,lies no@ use )re*greased and sealed*for*life dee)*groove ,earings.

&ea"y%duty rubber bloc' bearing mount

3.0

!ri"e (rrangement

3.1 *ear-+heel "ri#e


.orBue rea tionHC.o ever# a tion there is an eBual and o))osite rea tion.D .his state!ent !eans that ever# o!)onent that )rodu es or hanges a torBue @ill also exert an eBual and o))osite torBue tending to turn the asing. 'or exa!)leA @hen the engine ran6shaft exerts a torBue in a lo 6@ise dire tionA the #linder ,lo 6 @ill tend to rotate in an anti lo 6@ise dire tion.

A further exa!)le of torBue rea tion is sho@n in @hi h a tra tor @ith its rear driving @heels lo 6ed in a dit h. 0n this situation the driver !ust ,e arefulA ,e ause torBue rea tion is li6el# to lift the front of the tra tor rather than turn the rear @heels.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

Lever action of wheel 4hen the la@ stated a,ove is a))lied to rear axlesA #ou @ill see that so!e arrange!ent !ust ,e )rovided to )revent the axle asing turning in the o))osite dire tion to the driving @heels.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

3.2 ,otch-iss Open-%ype "ri#e


.@o rear leaf s)ringsA longitudinall# !ountedA are onne ted to the fra!e ,# a CfixedD )ivot at the frontA and s@inging sha 6les at the rear. At ea h end of the ex)osed or Co)enD t#)e )ro)eller shaft is fitted a universal :ointA @ith )rovision !ade for alteration in shaft lengthA @hi h o urs @hen the s)rings are defle ted. .orBue rea tion is resisted ,# la!)ing the axle to the s)rings ,# !eans of CUD ,olts. Under heav# driving onditions the s)rings @ill defle t u) at the front and do@n at the rearA and vi e versa during ,ra6ing.

&otsh'iss dri"e and suspension

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Module 4 Unit 3 & 4

Drive Shafts and Axles

3.3 Constant Velocity .oint


+ehi les @ith front @heel drive reBuire a s)e ial universal :oint to !aintain torBue at the @heel @hilst turning a orner. .he :oint is alled a onstant velo it# :oint. .his :oint does not have the disadvantage of the 5oo6es t#)e :oint @here t@o :oints are ne essar# to !aintain unifor! velo it#. 0n this :oint a !e hanis! is in or)orated ,et@een the I#o6esJ @hi h auto!ati all# align itself @hen the angle is for!ed ,# the t@o shafts. .he align!ent !a# ,e o,tained through the !ove!ent of steel ,alls in grooves or through the defle tion of ru,,er o!)onents * these defle tions neutralising the velo it# variation.

)*racta+ type constant%"elocity uni"ersal ,oint fitted to a front wheel dri"e a-le

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Module 4 Unit 3 & 4

Drive Shafts and Axles

4.0

.ornering

As the vehi le turns a ornerA the inner @heel !oves through a s!aller distan e than the outerA the @heels @ill ta6e the sa!e ti!e to turn the orner so the outer @heel !ust !ove faster to over the greater distan e. 0f a differential @as not e!)lo#ed a lot of t#re s ru,,ing @ould ta6e )la e and the vehi le @ould ,e hard to ontrol. 0n the differential asse!,l# the differen e in road resistan e on ea h side of the vehi le auses the sun @heel to rotate the )lanet gears @hi h in reases the s)eed of the outer @heelA de reases the s)eed of the inner @heel at the sa!e )ro)ortionA @hile !aintaining an eBual torBue at ,oth @heels.

/ote: UneBual rear t#re )ressureA ,ad road onditions also ,rings in the differential asse!,l# into o)eration.

0.0

1ear (-le

.he rear axle is @here the final in rease in torBue and de rease in engine s)eed ta6es )la e. 1e ause of the large* dia!eter @heels reBuired to arr# the heav# loadsA a ver# high torBue is reBuired at the end of the half shaft to turn the @heels and )ro)el the vehi le. .he axle asing is usuall# a ,an:o*t#)e asting @ith su))ort ,earings for the rear @heels at ea h end and a deta ha,le asting @hi h houses the differential gears and ro@n @heel asse!,l#.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

On light o!!er ial vehi lesA a onventional s)iral ,evel of h#)oid*t#)e rear axle onstru tion is used. As the load* arr#ing a)a it# of the vehi le in reasesA the axle ratio also has to ,e in reased to give the reBuired torBue at the rear @heels. 4hen this ratio rea hes a))roxi!atel# 7G1 the single ,evel gear axle gives @a# to a @or! and @heel arrange!ent or uses a dou,le redu tion arrange!ent to give the desired ratio @ithin reased strength.

2.0

&alf #hafts

.hree !ain !ethods are used to su))ort the half shafts in the rear axle ase. 0n all of the! the inner ends of the shafts are s)lined into and su))orted ,# the sun @heels of the differential asse!,l#. .he differen es lie in the arrange!ent of the hu, ,earing in relation to ,oth the ase and the shaft and in the for es or loads i!)osed u)on the shaft itself.

3.0

#emi%4loating

.he hu, and the half shaft areA in effe tA a one )ie e unit although the# !a# in fa t ,e s)lined or fitted together ,# !eans of a ta)erA 6e# and lo 6 nut. .he ,earing is arried on the shaft and is lo ated ,# a nut or a sleeve. .he outer tra 6 of the ,earing is fitted into a re ess in the axle ase and is lo ated ,# a retainer )late ,olted to the end flange of the axle ase. .his ,earing is usuall# sealed on one side to )revent ex ess lu,ri ant ruining the ,ra6e lining.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

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Module 4 Unit 3 & 4

Drive Shafts and Axles

4orces acting on the half shaft: 1. Shear for e due to the @eight of the vehi le. %. 1ending for e due to the @eight of the vehi le. 3. .orsional or t@isting for es due to the driving and ,ra6ing for e. 4. Side thrusts as the vehi le turns.

5.0

*hree%6uarter 4loating

.he ,earing is !ounted on the asing and is held against a shoulder ,# a lo 6nut and ta, @asher. .he hu, is !ade in t@o )artsA the inner )art fitting over the ,earing and also en losing a s)ring loaded oil seal. .he outer )art !a# ,e integral @ith the half shaftA ,e s)lined and interferen e fit u)on it or ,e se ured to the shaft ,# a ta)erA 6e# and lo 6nut. .he ,ra6e dru! !a# ,e integral @ith the hu, outer half or se ured to it ,# ounter sun6headed s re@s. .he ,a 6 )late !ounting flange is nearer to the entre of the axle than the se!i*floating design. .his design is !ainl# on light o!!er ial vehi les.

4orces acting on the half shaft: 1. 1ending for e due to side thrust @hen ornering. %. .orsional ;t@isting= for es due to the driving and ,ra6ing thrusts.

7.0

4ully 4loating

.his design is !ainl# used on heav# o!!er ial vehi les. .he hu, is a heav# forging or asting of steel and is arried on the axle ase ,# t@o heav# dut# o))osed ta)er roller ,earings. .he tra 6s of these ,earings are lo ated ,# shoulder and a lo 6nut and are ad:usta,le. .he hu, drive
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Module 4 Unit 3 & 4

Drive Shafts and Axles

)late is integral @ith the shaft and is se ured to the hu, ,# radiall# arranged set ,oltsA a gas6et fitted ,et@een the t@o. A s)ring loaded oil seal is fitted into the inner side of the hu, near the ,a 6 )late flange. .he half shaft !a# ,e re!oved @ithout re!oving the @heel.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

4orces acting on the half shaft: .orsional ;t@isting= for es due to the driving and ,ra6ing thrusts. /ote: 0n all of the designs des ri,ed the ,rea6ing of a half shaft @ill result in the loss of driving torBue due to the a tion of the differential unit.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

10.0 4ront%8heel !ri"e


*rans"erse engine layout .he transversel# !ounted engine is ,olted to a unit alled a transaxle. .his unit gets its na!e fro! the t@o @ords trans!ission ;a ter! used in A!eri a for gear,ox= and axle. 0n the )ast the general ter! Crear axleD often a))lied to the gearing as @ell as the axle asingA ,ut no@ada#s the various drive arrange!ents !a6e it ne essar# to restri t the use of the na!e Crear axleD to the !e!,er @hi h )erfor!s the axle dut#. .he t@o !ain o!)onents inside the axle of a rear* @heel drive vehi le are the final driveA e.g. ro@n @heel and )inionA and the differential.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

.he four*s)eed gear,ox has t@o shaftsG an in)ut shaft s)lined to the lut h and a !ainshaft onne ted to the final drive )inion. A ,evel gear final drive is ne essar# @hen the engine is !ounted longitudinall# ,ut in the la#out sho@nA the engine )osition allo@s the use of nor!al heli al gears. Drive fro! the final drive is trans!itted through the differential to the t@o drive shafts. S)eed variation due to drive shaft angularit# is )revented ,# using onstant velo it# universal :oints at ea h endK the in,oard :oint at ea h side ,eing of the )lunge t#)e. During a elerationA or at ti!es @hen the engine is used as a ,ra6eA torBue rea tion tends to !a6e the engine rotate a,out the ran6shaftA so suita,l# s)a ed engine !ountings are fitted to resist this !ove!ent. Driving thrust and ,ra6ing torBue are ta6en ,# the sus)ension !e!,ersA in )arti ular the tie ,ar fitted fro! the tra 6 ontrol ar! to the ,od#.

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Module 4 Unit 3 & 4

Drive Shafts and Axles

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FS Learning Innovation Unit pt! " #$%#& 'espil (oad )ublin #

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