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Student Workbook
LV12
Drive Shafts
(1)
LV12/SWB
Student Workbook for Technical Certificates in
Light Vehicle Maintenance and Repair
MODULE LV12
Drive Shafts (1)
Contents
Page ………... .Page
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Drive Train Layouts
In this unit we consider the means by which power is transmitted between the
power source and the driven wheel
The power produced by the engine in this illustration must be transferred from
the front to the rear of the vehicle. This is achieved by using a propeller shaft.
At the rear, the differential and half shafts transfer the power to the rear
wheels within a rigid axle casing.
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Power transfer
In this example the power is also transferred from the front to the rear of the
vehicle, but the differential transmits the power to smaller shafts, generally
referred to as drive shafts, before driving the rear wheels. This allows each
drive shaft to move independently of each other, rather than together in the
rigid casing of a conventional rear axle.
The position of the engine and transaxle close to the driving wheels of this
front engine front wheel drive example means that a propeller shaft is not
required.
Engine power is transferred directly to the differential and from there to the
driving wheels by two drive shafts.
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Mid engine rear wheel drive
In the same manner this mid engine rear wheel drive vehicle has an almost
identical layout.
This permanent four wheel drive layout is a combination of the front wheel
drive and rear wheel drive systems previously explained.
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Non-permanent four wheel drive
In this example of a non permanent four wheel drive vehicle engine power is
transferred to the rear wheels by a propeller shaft. However before leaving
the transmission the power is also transferred, via a transfer unit, to a front
differential and then to the front wheels.
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Operational requirements of drive shafts and propeller shafts
Steering condition
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Wheel rebounding
The angle (usually in the order of 20 degrees) through which the inboard joint
needs to transmit power is considerably less. The effects of suspension
movement require the drive shaft to change length and in this illustration the
inboard joint can slide in an axial direction. The distance is usually 25 – 50mm.
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Angular velocity
Variations in angular velocity are cancelled out by fitting a similar joint to the
other end of the shaft. The drive and driven shafts are also fitted parallel to
each other to smooth out variations in rotating speeds and torque.
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Fitting Propeller Shafts
Correct fitting
Incorrect fitting
It is vital that propeller shafts are fitted correctly. Propeller shaft ends must be
marked so that they can be refitted in exactly the same location. If this is
ignored vibration and noise will be the result. In the above illustration the top
shaft assembly is fitted correctly and the lower assembly is incorrect.
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Drive Shaft Joints
Construction of the Hooke’s joint
The Hooke’s joint illustrated has the advantage of simple construction. One of
the yokes is welded to the propeller shaft and the other yoke is an integral part
of a splined joint, which when inserted into the transmission output housing
provides a sliding joint. A forged spider is installed between the yokes and
needle roller bearings are installed in bearing cups press-fitted into the yoke
mountings. The cups are located in some instances by circlips or snap rings
and can be dismantled and serviced. Other versions use shell type bearings
instead. The cups are crimped in position and this version cannot be
dismantled.
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Drive shaft joints
A Birfield joint, sometimes known as a Rzeppa joint, has an inner race fitted
into an outer race between which steel balls are held in position by a steel
cage. Simple construction and the ability to transmit large torque through a
considerable angle means this joint is a common feature of drive shafts fitted
to front wheel drive vehicles. Because the intersecting point (0 in the
illustration) of the driving and driven shafts and the centre (P in the illustration)
of each ball bearing is constant this is a constant velocity joint. The rotational
speeds of the drive and driven shafts are identical.
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Tripod joint
The Tripod joint has three trunnion shafts on which three rollers, which have
roller bearings, run. The outer casing has a groove in which each of the
rollers is located. It is a relatively inexpensive joint which usually has axial
movement. The joint is encased in a flexible boot to retain the appropriate
lubricating grease. Failure of drive shaft joints are usually preceded by failure
of the flexible boot allowing the loss of lubricant and the ingress of road dirt.
In this constant velocity joint an inner race and an outer race have between
them a ball cage. As can be seen from the illustration the outer race has a
series of grooves in which the ball bearings run, providing axial movement.
The joint is encased in a flexible boot to retain the appropriate lubricating
grease. Failure of drive shaft joints are usually preceded by failure of the
flexible boot allowing the loss of lubricant and the ingress of road dirt.
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Similar constant velocity joint, the major difference being that, as can be seen
in the illustration, the grooves of the outer race are set at an angle to those of
the inner race. The joint is produced in two versions one with axial movement
and one without. The joint is encased in a flexible boot to retain the
appropriate lubricating grease. Failure of drive shaft joints are usually
preceded by failure of the flexible boot allowing the loss of lubricant and the
ingress of road dirt.
A drive shaft assembly will usually have a combination of two types of joint as
illustrated.
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Drive Shaft Construction
Propeller shaft
Propeller shafts are usually made from a high carbon steel tube to prevent
torsional and bending forces. Despite a careful balance process, and the
addition of balance weights, a single shaft having a joint at each end can
suffer from imbalance and vibration at higher rotational speeds because of its
greater length.
A two-piece shaft having three joints and a centre bearing has the advantage
of shorter shafts. Bending and high speed vibration is therefore reduced. The
longer shaft is often two piece with rubber insulators fitted in between.
Because of these advantages this propeller shaft arrangement is more
commonly used.
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Front propeller shaft (intermediate shaft)
To reduce vibration and noise even further the centre propeller shaft bearing
is mounted in rubber.
Whilst most shorter drive shafts are solid, longer drive shafts are often made
from a tube. This increases stiffness to match the rigidity of shorter shafts.
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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Drive Shaft Operation
During sudden acceleration the front of a vehicle tends to rise up. If drive
shafts of significantly different length are fitted, as in the top illustration, joint
angle Ø1 will be much greater than Ø2. This will cause the wheel attached to
the shortest drive shaft to attempt to ‘track or toe in’ further than the wheel
attached to the longer drive shaft. This will cause the vehicle to veer toward
the side with the longest drive shaft.
This can be prevented from occurring, by keeping joint angles and drive shaft
length the same. An intermediate shaft is often fitted, as shown in the bottom
illustration.
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Progress check
Answer the following questions:
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Copyright © Automotive Skills Limited 2003 Module LV12: Drive Shafts (1) Issue 1
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