14 传动轴Drive shaft.doc

PR-1Drive shaft PageNoticePR-2TroubleshootingPR-2DiagramsPR-3Disassembly and assemblyPR-4Technical requirement .PR-10 ININ PRFailurePossible reasonsTroubleshootingNoiseSpline of universal joint fork wearsReplace drive shaftIntermediate bearing wearsReplace intermediate bearingBearing of cross wears or seizuresReplace cross bearingVibrationDrive shaft runoutReplace drive shaftUnbalanced drive shaftReplace drive shaftBushing of transmission extension housing rear bearing wearsReplace bushingSeizure of the spline of universal joint forkReplace drive shaftNoticeNotice: never clamp the drive shaft bushing too tight with a bench vise to protect from deformation. The drive shaft of this model is mainly applicable for the automotive of Qi Sheng series.Troubleshooting Quality leads to futureDrive shaft- Disassembly and assembly PR-9Drive shaft assemblyFront welding conjunctionSnap ringSlip differential assemblyDrive shaft assemblyRear welding conjunctionUniversal joint assemblyNutNon-slip yoke assemblyGasketDrive shaft Component diagramSpring washerHex boltFlat washerIntermediate support assemblyDrive shaft assemblySpring washerDrive shaft nutDrive shaft boltAssembly markDrive shaft disassembly1. Remove the drive shaft universal flange yoke from the differential flange.(1) Attach assembly mark to the two flanges.(2) Remove four pairs of nuts and bolts.2. Disassemble the intermediate support bearing from the car chassis cross beam.3. Remove the transmission from the drive shaft.(1) Pull out the transmission from the universal joint fork.(2) Insert a plug into the transmission to prevent oil leakage.Drive shaft disassembly1. Attach assembly mark to the shaft and the universal join fork.2. Remove the intermediate support bearing from the drive shaft front section of rear axle. (1) Loosen the riveted part of nuts with hammer and chisel.(2)Remove nuts.Assembly markAssembly mark3. Remove the universal joint from the drive shaft rear section of rear axle.(1) Attach assembly mark to the universal joint fork and the shaft.(2) Pull out the universal joint fork from the shaft.Inspection of drive shaft parts1. Inspection of cross bearingCheck the wearing or damage of the cross bearing and replace it if necessary.2. Inspection of intermediate bearingCheck whether the bearing is capable of rotating freely and replace it in time if the bearing is damaged or worn out or fails to rotate freely.Replacement of cross bearing1. Attach assembly mark to the shaft and the universal joint fork.2. Remove snap ring(1) Beat the bearing outer pedestal ring slightly inwards(2) Dismantle four snap rings in each groove with two screwdriversA3. Remove cross bearing(1) Pull the bearing out of the drive shaftNote: Part A indicated in the drawing should be pulled high enough to prevent contact with bearing.(2) Clamp the bearing outer pedestal ring and tap the axel shaft slightly outwards.Note: repeat the steps and disassemble the bearing at the other end.(3) Assemble the two disassembled bearings to cross.(4) Pull the bearing on the universal joint fork out.(5) Clamp the bearing outer pedestal ring in a vice clamp and tap the universal joint fork slightly outwardsNote: repeat the steps and disassemble the bearing at the other side.4. Assembly of cross bearing(1) Spread lithium base lubrication to the cross and the bearing.Note: never apply too much lubricate.(2) Align the assembly marks on universal joint fork and shaft.(3) Install the new cross inside universal joint fork.(4) Assembly the new bearing to cross.(5) Regulate the two bearings to cause the width of the two bearings equal and maximum.5. Assembly of snap ring(1) Assemble two snap rings with equal thicknessesNote: never apply the used snap ring again.(2) Tap the universal joint fork slightly with a hammer till there is not clearance between bearing outer ring and snap ring.CuttingFrontAssembly mark6. Inspection of cross bearingCheck whether the cross bearing moves freely.Note: new cross bearing assembly can be conducted by the above steps.Assembly of drive shaft1. Install the intermediate support bearing to rear axel drive shaft front section.Note: when in assembly, the cutting on the intermediate bearing should be faced rearwards. 2. Install the flange joint to rear axel drive shaft front section.(1) Apply lithium lubricate to the spline of rear axel drive shaft front section.(2) Install the flange joint to the shaft subject to the assembly mark.Note: after the replacement of intermediate flange joint or rear axel drive shaft front section, the front universal joint fork of rear axel drive shaft front section and the rear universal joint fork of rear axel drive shaft front section should be faced to the same direction.(3) Lock the flange joint and screw up the new nut to press the bearing in place.(4) Screw off nuts.(5) Rescrew nuts.(6) Rivet nuts with a hammer and a punch.3. Assembly of drive shaft(1) Align assembly marks on flanges and connect the two flanges with four pairs of bolts and nuts.Note: after the replacement of intermediate flange or rear axel drive shaft front section, the front universal joint fork of rear axel drive shaft front section and the rear universal joint fork of rear axel drive shaft front section should be faced to the same direction.(2) Screw bolts and nuts subject to specified torque.Tightening torque: (64-80) NmAssembly markFrontAssembly of drive shaft1. Insert universal joint fork into a gearbox.2. Connect the universal joint flange of rear axel drive shaft with the corresponding flange of differential.(1) Align the assembly marks on the two flanges and connect the two flanges with four nuts and bolts.(2) Screw bolts and nuts subject to specified torque.Tightening torque: (64-80) Nm3. Install the intermediate support bearing to the car chassis cross beam.(1) Install the intermediate support bearing to the car chassis cross beam with two assembly bolts and tighten them by hand.(2) Check bearing pedestal which should be vertical to the drive shaft. Regulate the bearing pedestal if necessary.(3) Check the center line of the intermediate bearing and the center line should be coincided with that of the bearing pedestal when the automotive is unloaded. Adjust the bearing pedestal if necessary.(4) Screw bolts and nuts subject to specified torque.Tightening torque: (64-80) NmDrive shaft-Drive shaft (diesel oil) PR-11Technical Requirements1. DD1021L front, rear part(1) Keep 2 universal joints oil cup mouth in the same plane(2)