3.3. Cardan transfer

Possible malfunctions of cardan transfer, their reason and ways of elimination

Description of a design
Cardan transfer consists of two tubular driveshafts connected among themselves by the cardan hinge.

Fig. 3.56. Cardan transfer: 1, 39 – bolts connecting; 2 – the coupling is elastic; 3 – the plug aligning; 4 – flange; 5 – flange assembled; 6 – stopper; 7, 37 – nuts; 8 – epiploon; 9 – epiploon holder; 10 – safety arm; 11 – intermediate driveshaft; 12 – support cross-piece; 13 – ring; 14 – the support is intermediate; 15 – bearing; 16 – the ring is lock; 17 – reflector; 18 – fork; 19 – nut; 20, 21, 22, 23, 24, 25, 26, 27 – elements of fastening of an arm of safety and a cross-piece of a support; 28 – nut; 29 – flange; 30 – bolt; 31, 32, 33, 34 – a crosspiece with bearings; 35 – the ring is lock; 36 – driveshaft; 38 – washer

The intermediate driveshaft 11 (fig. 3.56) is connected to a secondary shaft of the transmission via the elastic coupling 2 and the flange 4 moving along the driveshaft on vents. The back end of the intermediate driveshaft is established in the intermediate support 14 attached to a cross-piece 12.
The intermediate elastic support 14 supports a middle part of cardan transfer and extinguishes its vibration.
The back driveshaft 36 is connected via the cardan hinge and a flange fork 29 to the leading gear wheel of the main transfer. The cardan hinge consists of the crosspiece 31 connecting two forks, cases of needle bearings 34, epiploons 32 which are put on hollow thorns of a crosspiece, and lock rings 35.
Balancing of cardan transfer is reached by welding of balancing plates, combination рисок on a flange 4 couplings and on the end of the intermediate driveshaft 11.

The forward driveshaft on the car with the transmission VAZ is 30 mm shorter than the driveshaft installed on the car with the transmission of fashion. Izh-2126 (as the VAZ box is longer than Izhevsk).

Through each 30 thousand km grease shlitsevy connection of cardan transfer from the elastic coupling with Fiol-1 lubricant, having turned off a stopper 6.
Definition of technical condition of cardan transfer
In cases of full or partial dismantling of cardan transfer it is recommended to check a condition of thorns of a crosspiece of needle bearings, the elastic coupling, an intermediate support, the bearing of an intermediate support, existence of a radial gap in mobile shlitsevy connection (about the elastic coupling) and motionless shlitsevy connection (about an intermediate support).
1. Install the car on the elevator or a viewing ditch.
2. Install the gear shifting lever in neutral situation and release the parking brake.
3. Turn off nuts of fastening of an arm 10 (see fig. 3.56) safety to a body floor and remove an arm.
4. Install a coupling collar (technological) on the elastic coupling 2 and, turning a shaft, turn off nuts of bolts of fastening of the coupling to a flange, remove bolts, and then a coupling collar.
5. Turn off nuts of bolts of fastening of the back driveshaft to a flange of the leading gear wheel of the main transfer of the back bridge.
6. Turn off bolts of fastening of an intermediate support 14 to an arm of a body and remove cardan transfer in the direction of a forward part of the car.

In order that after repair to establish the interfaced details on former places and to minimum debalance cardan transfer at its repair, before dismantling mark the mutual provision of details.

1. Easily striking with the hammer through a copper or aluminum mandrel a bottom of the case of each needle bearing, remove the screw-driver lock rings.

Fig. 3.57. Vypressovka of the needle bearing of the cardan hinge: 1 – emphasis; 2 – fork of the cardan hinge; 3 – bracket; 4 – the fork is flange

2. Establish a crosspiece from a forward shaft so that the lower ear of a fork of 2 (fig. 3.57) leaned on an emphasis 1, and by means of a press, pressing through a bracket 3 and a fork, a vypressuyta the needle bearing from the lower eye. Then turn a crosspiece with forks on 180 °, insert it into adaptation and a vypressuyta the second bearing of the same fork again.
3. Separate driveshaft forks. Put on needle bearings free thorns of a crosspiece, insert a fork into adaptation so that the lower eye leaned on an emphasis 1, and by means of a press, pressing through a bracket 3 and the case of bearings a crosspiece, a vypressuyta the lower, and then top bearings.
4. Separate a fork with a crosspiece.
5. Similarly disassemble the hinge of cardan transfer from a flange fork.

Fig. 3.58. Svyaty forks from the forward driveshaft: 1 – stripper; 2 – stripper levers; 3 – fork of the forward driveshaft; 4 – forward driveshaft

6. After dismantling of hinges of cardan transfer turn off a nut 19 (see fig. 3.56) fastenings of a fork of the 18th cardan hinge to a forward shaft. Remove a fork a stripper of 1 (fig. 3.58).

Fig. 3.59. Removal of an intermediate support from the forward driveshaft: 1 – intermediate support; 2 – shlitsevy end of the forward driveshaft; 3 – press punch; 4 – podkladny half rings

7. Under a press by means of podkladny half rings of 4 (fig. 3.59) remove from a forward shaft an intermediate support assembled with the bearing and a reflector.

Fig. 3.60. Removal of the bearing from an intermediate support: 1 – level; 2 – pads; 3 – stripper; 4 – captures; 5 – intermediate support

8. For dismantling of an intermediate support remove a lock ring, then a stripper of 3 (fig. 3.60) to a vypressuyta the bearing from a support.
Check of a beating of shaft
Forward shaft
Install a forward shaft on the stand and, turning a shaft, check a beating: on a pipe at distance (180±10) mm from a welded seam from the forward end it should not exceed 0,3 mm, on the forward end about a shlitsevy part – 0,2 mm.
Check a gap in shlitsevy connections. An admissible radial gap in shlitsevy connections of 0,3 mm.
Back shaft
Install a back shaft on the stand and, turning a shaft, check its beating on a pipe at distance (400±10) mm from a welding seam from any party of a shaft. The beating should not exceed 0,3 mm. If the beating is more, execute editing of shaft under a press. At a big beating replace a shaft.
Definition of technical condition of cardan hinges
Check a condition of cases of bearings, needles, thorns of crosspieces and epiploons. At wear or damage of any detail of the hinge replace a crosspiece assembled with bearings.
Definition of technical condition of an intermediate support
Turn an internal ring in both directions, having pressed it to external, at the same time the bearing has to rotate smoothly and without noise. If the bearing is worn-out or damaged, replace it new.
Check an intermediate support. Replace the deformed support new.
Assembly of shaft
You carry out assembly of driveshafts upside-down taking into account the following instructions.
1. Apply lubricant No. 158 on shlitsevy connections.
2. A nut of fastening of a fork of the forward driveshaft tighten the moment of 88-98 N · m (9–10 kgfs · м).

Fig. 3.61. Ustavovka of the bearing on an intermediate support: 1 – mandrel; 2 – bearing; 3 – intermediate support

3. Before a press fitting in an intermediate support grease the bearing with Litol-24 lubricant. For a press fitting use a mandrel of 1 (fig. 3.61). Establish a lock spring ring of the bearing in a support pro-point.

Fig. 3.62. Installation of an intermediate support on the forward driveshaft: 1 – mandrel; 2 – intermediate support; 3 – back part of the forward driveshaft

4. Put on a bearing mud-reflector the back end of the forward driveshaft, then a mandrel of 1 (fig. 3.62) press a support with the bearing and put on the second mud-reflector.
5. Napressuyte on a shaft a fork of the forward driveshaft also tighten a nut of its fastening the moment of 88-98 N · m (9–10 kgfs · м).

You carry out assembly of crosspieces of the driveshaft with forks and bearings according to earlier made marking.

Assembly of crosspieces

Fig. 3.63. Napressovka of an epiploon on a crosspiece

1. Establish on crosspiece thorns epiploons of needle bearings and by means of a press and two cylindrical mandrels (fig. 3.63) press them in pairs against the stop in fillets of crosspieces.
2. Fill completely with crosspiece opening lubricant No. 158.
3. Grease with lubricant No. 158 rollers of the needle bearing.
4. Insert a crosspiece with epiploons into one of forks.

Fig. 3.64. Press fitting of the needle bearing of the cardan hinge

5. Place a fork in adaptation, press needle bearings (fig. 3.64) in its eyes, and then establish lock rings. In the same way press two other bearings in eyes of other fork and establish lock rings.
6. Check ease of the movement of forks of Cardan which have to by hand freely, without jamming to move in any plane to a corner not less than 15 °.
Balancing check
At detection of an imbalance check balancing of cardan transfer at the special stand. The equilibration is reached by a privarivaniye of metal plates.
Install cardan transfer on the car upside-down. Assembled tighten nuts and bolts of fastening of driveshafts a dynamometer key the inhaling moments specified in the appendix 1.