Cardan shaft crosspiece - DIY replacement

The driveshaft and its crosspiece - why are they so important

The driveshaft - in common parlance just a cardan - is an important part of the transmission in the design of rear-wheel drive and all-wheel drive vehicles. Its task is to transmit torque at an angle. It is also called the “car support”, as it provides the rigidity necessary for proper functioning.

The cardan consists of two hollow pipes connected by a cross. The crosspiece is the heart of the cardan shaft, because it is responsible for transmitting rotation. In essence, this is a cross-shaped hinge that moves due to bearings. In addition to its main functions, it helps the car maintain balance on uneven roads and dampens the resistance of the driveshaft.

The driveshaft in general and the spider in particular are the heart of the transmission. These devices provide a smooth and even ride of the vehicle, sensitive control and a comfortable ride. Their failure is fraught with many troubles: loosening of the fastening, play between the two shafts and an increase in the load on the crosspiece can lead to a breakage of the shaft and, as a consequence, to an emergency. How to prevent this and notice the problem in time?

How to find out if the crosspiece is out of order

Replacing the driveshaft on a VAZ 2107
This is the central link in the driveshaft. As we have already noted, it is the crosspiece that transmits torque between the gearbox and other units. That is, the shaft rotates precisely thanks to it. If a breakdown occurs on the road, every driver should be able to repair the car. This means you need to know how to remove the cardan and how to repair it. And this is especially difficult when you consider that the entire device often fails.

It is important to use a puller when disassembling; when removing the retaining ring, it must be undamaged. If you hear a knocking sound when driving the car, it means you have problems with the driveshaft

Grinding of parts may also be heard. Never install a puller without first removing the retaining ring; this cannot be ignored. A couple of hundred kilometers will pass, and the cardan will completely fail, causing an accident.

The size of the cardan is small, but this device can be the reason why the car does not move.

Problems with the driveshaft occur when the car is driven by a reckless driver, especially on a bad road. The hinge easily fails, as all the dirt from the road and water after rain get on it. Using a puller, you can easily dismantle the faulty part right on site. Also, the cardan does not work well if you move over rough terrain for a long time.

Signs of a broken universal joint

An experienced driver who knows his car well usually has no difficulty in noticing even the slightest change in the car's performance, but problems with the driveshaft often become noticeable when it is too late. Experts note that the easiest way to determine if a crosspiece is broken is by sound. The driver himself cannot always hear it, so it is better to check the car with an assistant located outside the cabin. What should the following sounds convey:

• Knocking and knocking noises when the gearbox is turned on clearly indicate that the crosspiece is faulty. Its inability to hold the shaft creates a misalignment - backlash, which is the cause of sharp impacts.
• Creaking noise when driving or accelerating may be due to deformation of the spider bearing. If you do not carry out an urgent replacement, the hinge will only continue to deteriorate.
• Vibration of the chassis can be a manifestation of many malfunctions, but the most common is wear of the crosspiece bearings.

When is it time to change the universal joint?

Cardan drive: Replacing the driveshaft crosspiece

The cardan shaft crosspiece is one of the most important parts of the cardan drive. Not only the efficiency of torque transmission, but also safety on the road depends on the quality of workmanship and correct installation of the universal joint. That is why the enterprises of the Vilyuy group of companies place special emphasis on the quality of the crosspieces produced. After all, at the slightest malfunction of the cardan shaft crosspiece, an imbalance occurs, which can lead to failure of other elements of the machine.

If a knocking sound occurs when starting to move, changing gears or sharp acceleration, as well as when noise and vibration of the machine appears when driving in a certain speed range, check to see if the driveshaft crosspiece may need to be replaced. Moreover, the crosspiece of the rear propeller shaft, which is attached to the flange of the drive gear of the main gear, wears out faster. It is she who is more loaded.

Of course, these symptoms may mean not only failure of the universal joint . Therefore, it is necessary to carry out an initial diagnosis. By visual inspection, assess the damage to the crosspiece needle bearing seals and the clearance. Holding the propeller shaft with one hand and the flange with the other, rotate them in different directions. The appearance of play will indicate severe wear of the part. But if the wear is not great or the cuff of one of the bearings is damaged, this can only be determined by removing the driveshaft.

If the driveshaft spiders are worn or damaged, they must be replaced to prevent damage to other machine parts. Remember, by saving on replacing the driveshaft crosspiece, you risk spending money on replacing the entire driveshaft assembly.

It is better to entrust the replacement of universal joints to professionals and contact a specialized service. However, if you decide to fix this problem yourself, then to replace it you need to prepare a tool and, of course, buy a new driveshaft crosspiece. Please note that the Vilyuy cardan crosspieces are supplied complete with locking rings (when the locking is performed by them). This is done for the convenience of customers and for safety purposes, since it is not recommended to install old retaining rings when replacing the cardan crosspiece!

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Causes of crosspiece malfunction

Often the damage is so serious that only a complete replacement of the hinge, or even the entire cardan, can correct the situation. Of course, no one will be happy with the extra expenses, not to mention the downtime of the car. Therefore, it is a good idea to try to minimize the risk of failure. The two most common causes of hinge failure are:

• The crosspiece is a fairly strong part, but even it is subject to wear. This is especially noticeable on trucks. Mechanical shocks and careless driving significantly reduce the service life of the joint.
• Incorrect installation and balancing. Most often, used cars suffer from this, whose owners independently repaired the cardan. When installing the crosspiece, accuracy and reliability of fastening is important, otherwise vibrations will occur that can destroy the part.

Repair or replacement of the cross

The degree of damage to the hinge and the likelihood of successful repair can only be determined by removing and disassembling the crosspiece. Usually this procedure is carried out on a dismantled cardan.

The decision to replace or repair is made based on the appearance of the hinge and its parts. If we are talking about one or more worn out bearings, then this problem can be easily solved without complete replacement. However, if deformation of the crosspiece is visible - dents, cracks, bends - then repair is not enough.

Unfortunately, not all car owners follow these rules. There are many examples of unsuccessful attempts at makeshift repair of the spider, which only led to faster destruction of the driveshaft, driving problems and emergency situations. Any mechanical impact, especially on an already damaged hinge, reduces its ability to bear loads, even if as a result of these actions its appearance is restored. If repairs are possible, they must be carried out by trained personnel.

Design and principle of operation

The HF includes several elements:

• shaft,
• two crosses,
• sliding fork, seals,
• fastening parts, in particular the suspension bearing,
• a number of other elements, which depends on the type of design.

The HF may include several sections - one, two, three or more. The dimensions and weight of the shaft depend on the dimensions of the vehicle. The device of a single-section propeller shaft includes a central part and tips with crosses attached to it.

Cardan shaft device

The functionality of the cardan transmission (GT) system is ensured by hinge mechanisms based on crosspieces. Cross

enable two mating shafts to rotate at varying angles relative to each other. The highest efficiency is achieved at a rotation angle of 0°...20°. In the case when this indicator is exceeded, the cross is subject to significant overloads. In addition, the shaft loses balance and vibration appears.

Another important element is the sliding spline connection

KP. Its use is due to the fact that the car’s suspension, especially when overcoming obstacles, significantly stretches in height. The gearbox or transfer case, to which one end of the shaft is attached, is rigidly fixed inside the body, and the axle gearbox (the second point of attachment of the gearbox) is connected to the suspension. As a result, when moving over an obstacle, the distance between the gearbox and the axle gearbox increases. In this case, the HF must “stretch”, and the sliding spline connection helps it do this.

Another important part of the gearbox is the outboard bearing.

. It provides additional support for the composite shaft, holding it in place and not preventing it from rotating. The bearing bracket is attached to the body. The number of bearings depends on the number of sections that make up the shaft.

How to choose a crosspiece for your car

If after all the diagnostic procedures it becomes clear that the car cannot drive for a long time without a new part, it’s time to think about choosing a replacement joint. What should you pay attention to?

• Manufacturer. It is best to give preference to well-known names. Among the most popular and high-quality ones are GWB, GKN, HD Parts.
• The appearance of a part can tell a lot. If traces of rough machining, burrs and other defects are visible, then this is a product of low quality.
• The choice of cross is made according to the shape and size of the bearing cups - they must correspond to a tight fit.

Oil leak at the junction of the gearbox and the front part of the driveshaft

Found on cars with a spline connection located in the box or transfer case.

Causes of leakage:

1. Oil leakage occurs due to a defective oil seal in the box. The O-ring hardens over time, forming a gap between the movable cardan rod and the oil seal. Eliminated by replacing the oil seal in the box or transfer case.
2. Damage to the mirror on the movable rod (spline connection) of the propeller shaft. The appearance of burrs or roughness on the splines. Treated by replacing the splines. As a temporary option, burrs can be cleaned off with sandpaper, which reduces leakage.

Heavy knocking or knocking immediately after turning on the gearbox, vibration when accelerating

The main reason for shocks or knocks when there is a load on the driveshaft is backlash!

1. The most common cause is a faulty driveshaft spider. When it is destroyed, a strong backlash appears and, as a result, impacts. The crosspiece needs to be replaced.
2. Loosening the propeller shaft bolts. Carefully inspect all bolts and tighten securely. If the bolts have not been touched in the near future, then the problem is not with them.
3. The movable splines of the propeller shaft are severely worn. To eliminate the problem, replace the cardan splines.
4. There is a lot of play in the bearing kit. Usually accompanied by frequent replacement of the propeller shaft bearing. Treat by installing the kit under the support.

Intermittent or constant squeaking

Periodic squeaking occurs when you press the gas pedal, and disappears when coasting. In some cases, the appearance of a squeak depends on the temperature outside, as well as the angle of operation of the hinge - cross or CV joint.

1. The driveshaft crosspiece is jammed. As a rule, it is accompanied by the presence of rusty smudges on the crosspiece. Syringing won't help. Jamming means that the cup bearing has become deformed. The next stage will be its destruction. It is necessary to replace the hinge as soon as possible.
2. The CV joint of the cardan wedges in the operating range. Go through, carefully inspect for wear and tear and lubricate, if that doesn’t help, replace.

Checking the D-Pad for Problems

To ensure long service life of the gimbal and retaining ring, it is important to check them carefully. To do this, remove the cardan to the surface using a puller

Fortunately, this part is small in size, which makes it easy to inspect the element for cracks and gaps. To do this, simply rotate the crosspiece parts in different directions. If there are problems, you will notice it immediately. Take the flange with one hand, the driveshaft with the other and rotate in different directions. Is there any play? This means there is a problem with the device.

You may have to completely replace the steering, but if only the hinge is broken, then its dimensions allow you to repair the part yourself using a puller. This way you will correct the operation of the cardan, which is the steering wheel in the car.

The steering is easy to change. To do this you need to take the following steps:

1. the mounting bolts are unscrewed,
2. the cardan is dismantled, fortunately the dimensions allow this to be done,
3. the nuts should be unscrewed,
4. the locking ring opens,
5. the cross is removed.

Vibration is the main failure of the cardan

Before troubleshooting the driveshaft, make sure there is no imbalance on the wheels.

If vibration of the driveshaft occurs in a certain speed range (from 60 to 80 km/h, from 90 to 120 km/h), this is good vibration, which is eliminated by balancing the driveshaft. As a rule, this kind of vibration appears after repairing the driveshaft: replacing the crosspiece, bearing, shortening and lengthening, or disassembling and reassembling the driveshaft not according to factory marks.

If the vibration began suddenly at a certain speed and constantly increases as it increases. However, the driveshaft was not repaired. The following faults need to be checked:

1. Impaired smoothness and play in the crosspieces. Worn hinges need to be replaced.
2. Ingress of a foreign body (up to grains of sand) when installing the cardan on the axle, transfer case, or gearbox. Clean the cardan flanges and receiving flanges on the vehicle from dirt.
3. Play in the movable splines or fixed splines (support set) of the propeller shaft. The spline connections need to be replaced.
4. Separation or extreme corrosion of balancing plates. Inspect the cardan; when the plate is torn off, the place of its attachment is very clearly visible. Eliminated by balancing.
5. Dirt stuck to the driveshaft. Clean the shaft from dirt.
6. A bent pipe due to a mechanical shock when hitting a cobblestone or curb. In some cases, it can be treated by straightening the pipe using a hydraulic press. On average, if the pipe is deformed by more than 1.5 millimeters, it is replaced with a new one.

Removing and disassembling the unit

To make work easier, it is recommended to engage first or second gear, which will lock the cardan. Before you begin removing the driveshaft, you should definitely mark the position of the forks relative to the shaft and gearbox flange. This will allow you to correctly install the cardan during assembly, thereby avoiding imbalance and runout.

First you need to loosen the bolts securing the rear fork to the gearbox flange. This can be done using open-end wrenches (usually 12-13 mm in size). Then we dismantle the intermediate support of the outboard bearing. It will be more convenient to use a socket wrench or a 13mm socket. Now you just have to carefully pull the driveshaft out of the splines on the gearbox side.

After removing the shaft, it must be cleaned of dirt. Using a special puller or available tools (flat-head screwdrivers and an awl), remove the retaining rings from the shaft eyes and the universal joint fork. Be extremely careful and protect your eyes. Retaining rings are made of spring steel, so when they are removed using improvised means, they tend to fly out of the grooves in an unknown direction.

Next, you need to select a cylindrical spacer with a diameter slightly smaller than the eye on the shaft. The old crosspiece has already exhausted its service life and is of no value to us. Therefore, using a hammer to knock out the plug through the spacer, it is opposite to the direction of impact. Similarly, it is necessary to remove the remaining plugs and remove the cross.

After the cross is removed, thoroughly clean the eyes from any remaining dirt so that it does not get into the new bearings during assembly. You can use gasoline and a brush. After cleaning, you should carefully inspect the eyes. If necessary, use a round file to remove any burrs that have formed inside the lugs. The cork should fit in with a slight tension, but it should not bite.

How to make sure that the vibration is from the cardan

While driving, use the tachometer to notice the engine speed at which vibration occurs. Then, in another gear, increase the speed until the same phenomenon occurs.

1. If vibration occurs at the same speed, but in different gears, then the cause of the malfunction is not in the cardan, since its speed was different.
2. If the vibration disappears or decreases when operating in a different gear at the same engine speed, then check the possible causes of the malfunction described above.

CV joint replacement

When is it time to change? It's easy to check the condition of CV joints. Turn the front wheels to the maximum angle, and then try to move away. If you hear a sharp metallic crunch, then the CV joints need to be replaced as soon as possible. Additional checking of CV joints is possible when moving in a straight line. Jerking of the car during acceleration means a problem with the joint. Russian and imported cars, as well as even special equipment and industrial installations - all this is included in the scope of work of the MotorService company. Masters use foreign equipment and provide balancing accuracy higher than the factory one.

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