205-00-1 Drive Shaft System – General Information 205-00-1

Section 205-00 Drive Shaft System – General Information

Applicable Model: Boomday

CONTENTS PAGE
Specifications
Specifications ................................................................................................................................ 205-00-2
Descriptions and Operations
Drive Shaft System ........................................................................................................................ 205-00-3
Diagnosis and Testing
Drive Shaft System ....................................................................................................................... 205-00-4

2011 Boomday & Boarding Workshop manual

205-00-2 Drive Shaft System – General Information 205-00-2
Specifications

Material Specifications

Item Specification
Grease 2# lithium-based
Gear Oil APL GL-5 80W-90

Capacity

Item L
Front Axle
Gear Oil (167 mm) 1.0
Gear Oil (194 mm) 1.5
Rear Axle
Gear Oil 7A Series 1.6 ~ 2
Gear Oil TL-A Series 2.5

2011 Boomday & Boarding Workshop manual

205-00-3 Drive Shaft System – General Information 205-00-3
Descriptions and Operations

Drive Shaft System

The power of drive shaft system is generated by
engine and to be transmitted to gear box. Drive
unit transmits engine torque to axle via drive
shaft.
● In 2WD vehicle, the power is transmitted to
drive shaft and subsequently to rear axle
through gear box.
● In 4WD vehicle, the power is transmitted
through gear box and transfer case. Transfer
case transmits the power to rear drive shaft
and then rear axle.
When transfer case joins, it transmits the power
to front axle through front drive shaft. Rear drive
shaft is linked to output shaft of transfer case.
Front drive shaft and transfer case are linked to
front axle. The length of drive shaft is controlled
by a flange shaft furnished with splines. Engine
torque is transmitted to axles through driver
pinion of dive gear ring. With gear ring installed
on differential carrier, the power is transmitted
to rear semiaxis or front semiaxis through gears
inside differential carrier. These semiaxises
propel the power of driving wheel.

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205-00-4 Drive Shaft System – General Information
Diagnosis and Testing
Drive Shaft System
Inspection and Confirmation
The phenomenon of some axle noises and drive unit
failures bears the similarity to the failures of engine,
gear box, wheel bearing, tire and other components
of vehicle. Therefore, it is imperative to ascertain that
the cause of failure lies in front or rear axle before
any adjustments, repairs or installations of new
components being made.
The phenomenon of drive shaft vibration is shared by
the front engine accessory drive (FEAD), engine, gear
box or tire. It is imperative to ascertain that the cause
of failure lies in drive shaft before any adjustments,
repairs or installations of new components being
made.
Some of the failures are caused by antiskid differential.
Check identification label of the vehicle and axle, verify
the type of differential.
Acceptable Noise Degree
AT T E N T I O N : G e a r d r i v e u n i t m i g h t
generate some noises. Some noise
is acceptable, which can be heard
under certain speed or various of drive
conditions, such as one newly paved tar
road. Slight noise is harmless to axle,
thus can be deemed as normal.
It is acceptable for vehicle equipped with antiskid
differential to generate slight noise “ka-da” when
turning after long time of drive. It brings no harm
to differential performance, thus can be deemed
as acceptable.
Cardan Joint Inspection
Place vehicle on a lift-type lifter, refer to section
100-02 for more information. Turn the drive shaft
manually. Check the cardan joint for coarseness
and tenaciousness. Install a new cardan joint in
case of evidence of tenaciousness, over worn
or incorrect fixation. Refer to section 205-01 for
more information.
Leakage Analysis
Clean spill area thoroughly to find leak source.
The following faults can lead leakage to axle:
● Axle lubricant level is too high.
● Drive shaft or differential seal is worn or
damaged.
● Differential housing cracks.
2011 Boomday & Boarding Workshop manual
205-00-4
● Flanged yoke seal is worn or damaged.
● Driving gear flange is scratched or damaged.
● Axle housing does not seal.
● Ventilating Pipe blockage.
Conduct repair to axle if needed. Ensure the correct
lubricant level. Refer to parameter-specifications in
this section for more detailed information.
Axle Ventilating Pipe
ATTENTION: Install a new axle ventilating
pipe when cleaning is impossible.
Plugged ducts lead to excessive wear of seal lip
due to the accumulation of internal pressure. Check
the ventilating pipe if leaks occur. Make ensure no
twist (s) on ventilating hose. Remove the ventilating
hose from ventilating mouth and clean foreign
body inside the hose by repeatedly stabbing into
ventilating pipe with metal wire or a small diameter
hex wrench. Then connect the hose.
Flanged Yoke Seal
The leakage of driving gear seal is generated by
the following reasons:
● Drive gear seal is not properly installed.
● Poor finishing of axle journal surface.
Any damage (scratches, pits, grooves or other
defects) to seal holes will distort seal casing and
lead the leaks through the outer edge of drive
gear seal.
If not properly installed, drive gear seal may be
torn, cut or grooved. The spring which fixed gear
pinion to drive gear flange may be tapped out
and lead to the oil leakage through seal lip.
Rubber seal lip part in contact with gear oil may
harden and result in cracks. The contact point of
drive gear flange and rubber lip may darken, thus
indicate overheating fault. Scratches, cracks,
grooves or surface roughness on drive gear
flange journal can lead to leakage.
Metal shavings stuck to seal lips may cause oil
leakage. This can cause grooves on drive gear
flange and result in seal wear.
For drive gear, wear equal to or greater than
1.27mm can be categorized as excessive wear.
A new drive gear flange must be installed if any
one of these conditions exists.
To install a new drive gear seal and check vents
to ensure cleanness and absence of foreign
material if seal leaks.
205-00-5 Drive Shaft System – General Information 205-00-5
Diagnosis and Testing

Semiaxis Seal Beating of Guide Pin

If semiaxis seal leaks for incorrect installation, the 1. To place special tool as close to the surface of
same damage as in the case of drive shaft seal hub or flange as possible. Set dial gauge zero
leakage will occur. Semiaxis oil seal hole shall be so that the pointer can deflect in both directions.
clean, seal lip shall be gently handled to avoid break
and crack. Scratch as well as groove or roughness
is not allowed to appear on semiaxis surface.
Differential Seal
Refer to section 205-02 (rear axle) or section
205-03 (front axle) for more information on
differential seal.
Vibration Analysis
WARNING: Vehicle furnished with antiskid
differential always keeps two wheels in
driving state, when one wheel is lifted off
the ground as engine drives the rear axle,
the other wheel in contact with ground will 2. Rotate hub or flange for one full circle and record
drive the vehicle off test desk or jack. To the maximum and minimum measurements.
ensure all two rear wheels are off ground. The deviation between maximum and minimum
Few vibrations are caused by front axle or rear axle. measurements is the total beating amount of guide
For reported vibration failure, refer to section 100-04 pin. The beating amount shall not exceed 0.15mm.
for diagnosis procedure, unless there are reasonable Beating on Wheel Hub or Semiaxis Flange End
grounds to suspect that failure from axle.
ATTENTION: Check the beating of semiaxis,
Beating of Hub or Semiaxis Flange Bolt Circle if semiaxis assembly is removed. The
ATTENTION: Brake disc shall be removed maximum beating amount allowed for
for beating amount measurement. unprocessed part of semiaxis is 3.0mm. This
1. To place special tool perpendicular to hub bolt or beating amount will not induce vibration.
semiaxis flange bolt, and as close to the surface 1. To place special tool on the end face of hub or
of hub or flange as possible. Set dial gauge zero flange and as close to the end surface of hub
so that the pointer can deflect in both directions. or flange as possible. Set dial gauge zero so
that the pointer can deflect in both directions.

2. Rotate hub or flange until the touching with next

bolt. Record the measurement and continue
to measure until each bolt is checked. The
deviation between maximum and minimum
readings is the total beating amount of hub
flange bolt or semiaxis flange bolt. The beating
amount shall not exceed 0.38mm.
2. Rotate hub or flange for 1 full circle and record
the maximum and minimum measurements.
The deviation between maximum and minimum
measurements is the total beating amount of end
face. The beating amount shall not exceed 0.254mm.

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205-00-6 Drive Shaft System – General Information 205-00-6
Diagnosis and Testing

Driving Gear Lever and Driving generated by a specific gear bearing. It is easy
to identify bearing that is worn / damaged. Check
Gear Flange the large end of pin roller for wear and tear.
Check driving gear flange for beating amount when A gear bearing shall be replaced when original mixed
all other inspections failed to identify vibration cause. radius of the gear bearing was ground to sharp edges.
The excessive beating of drive gear flange can ATTENTION: The low and slow rumble common
be attributed to the incorrect assembly of drive in worn / damaged wheel bearing is usually
gear flange seal. The spring on seal lip shall be caused by an external luggage rack or tire.
checked for fixation prior to the installation of new Wheel bearing noise manifests itself in low and
gear ring and drive gear. slow rumble which would be mistaken for drive
gear bearing noise. Check the outer ring of wheels
Semiaxis bearing for fall-off and the pin roller for loss /
ATTENTION: When checking dirt-proof damage. A new wheel bearing should be installed
boot, observe the edge of dirt-proof boot for if any related problem was identified.
obvious cleft. Any cleft(s) shall be removed.
● Check dirt-proof boot for cracks, tears or signs
of cracking.
● Check the bottom of vehicle for any signs of
splash of lubricants around constant velocity
cardan joint. This is an indication of dirt-proof
boot/clamping band damage.
Axle Noise
ATTENTION: Prior to disassembly diagnosis
on axle and repair of gear noise, it is
imperative to exclude the tyre, venting
system, plaque, roof luggage rack, semiaxis,
wheel hub and etc. parts from source
of trouble first. The diagnosis shall be If a wheel bearing is damaged, the upper pin
performed in accordance with procedure. roller of semiaxis may also be damaged. Install a
The following noises are caused by specific new axle if any problem is identified.
reasons, of which shall be diagnosed through
observation after disassembly. The initial
diagnostic clues are noise types of road test.
Gear Whistling Noise
The whistling noise generated by gear ring or drive
gear can be attributed to incorrect connection of
gears, gear damage or bearing tightness fault.
Bearing Whistling Noise
Bearing whistling noise is similar to the sharp oral
whistling. It is usually generated by the wear /
damage of drive gear bearing which controls the
speed of drive shaft. It may happen at any drive
speed. This noise can be distinguished from gear Bearing Rumble
whistling noise by changing speed. Bearing rumble sounds like the collapsing of
It is ATTENTION worthy that usually drive gear marbles. This is usually due to damaged / broken
bearings can generate sharp whistling at any wheel bearings. Low-frequency noise is likely to be
speeds. However, the noise varies with different generated, if the shaft rotation speed is 1/3 of that
drive stages if only one gear is worn / damaged. of drive shaft . Wheel bearing can also generate
A new gear bearing shall not be installed unless howling noise similar to gear noise. This is especially
it was scratched, damaged or the noise is evident by four-wheel drive mode.

2011 Boomday & Boarding Workshop manual

205-00-7 Drive Shaft System – General Information 205-00-7
Diagnosis and Testing

Semiaxis Bearing Noise Tap

The noises of semiaxis bearing and gear are similar Tap may occur at all driving stages. Its cause can
to the sound of differential drive gear bearing. be categorized to several types, including the
Different from gear noise, semiaxis bearings damage of gear teeth or gear set.
generate noise in all driving modes (driving,
sliding and drifting). When a vehicle is traveling
at a speed by which noise occur, the gear box in
neutral position will continue to generate noises. If
a vehicle is noisy, the suspicious semiaxis can be
removed to install a new bearing and axle oil seal.
The vehicles shall be re-examined for noise prior to
the removal of other internal parts.
Rattle
Rattles common in sliding drive stage are usually
generated by the excessive gap between differential
gear wheel hub and differential housing hole.
A damaged sliding side of gear tooth will lead to the
In most cases, one of the following situations will occur.
same noise as rattle. A small tooth scratch or tooth
edge bending will lead to the occurrence of noise. 1. Tooth damage of driven side is usually the
Clean the scratches or bending of a ring gear with cause of tap. It can generally be corrected by
a small mill wheel. A new gear should be installed grinding damaged area.
if the damaged area is larger than 3.2mm.
Check the primary driven gear to remove gear
lubricant with detergent. Dry the gear by wiping or
blowing with compressed air. Seek out scratch or
damaged teeth. At the same time seek out cracks
or other damages. Install a new primary driven gear
if the gear is scratched or seriously damaged.

2. ATTENTION: Instead by feeling, the

axial clearance shall be measured by a dial-
type meter furnished with fixed fixture. Taps
may be caused by excessive gap between
output and input of semiaxis.
The maximum allowable gap of semi-floating axle
is 0.76 mm. As the speed of semiaxis is slower
than drive shaft , the frequency of taps may also
accordingly drop.

Axle housing shall be cleaned to remove damage

causing particles if rupture of metal parts occurs. In
this case, damaged part in the housing axle shall
be reinstalled.

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205-00-8 Drive Shaft System – General Information 205-00-8
Diagnosis and Testing

Dull Metallic Noise 7. Measure the length of the mark which is left by
Dull metallic noise can be heard when automatic the crayon or chalk. If the length of the mark
gear shift operates at reverse gear or forward is 25.4 mm or less, the rear axle clearance is
gear. The noise can also be heard when air within the permitted range.
throttle opens or closes. It is generated through ● Check the following points if the tag is longer
clearance in transmission system or looseness than 25.4 mm:
of suspension parts. It can be sensed or heard at - Differential planet pins on differential housing
axle. Refer to clearance inspection in this section. and elongation and extension of holes.
Moreover, dull metallic noise can be heard at - The anti-thrust washer of differential planet
starting moment. It is generated as motor torque gear or anti-thrust washer of differential
shifts the vehicle weight, thus changing the semiaxis gear shaft is missing.
angle of power transmission system, the slide
- Differential planet gear shaft and the hole with
of drive shaft expansion coupling to output shaft
scratches.
is prohibited. This condition can be rectified
by applying lubricants to splines of expansion - Excessive clearance between ring gear and
coupling. Refer to section 205-01. gear. Check the clearance according to the
type of rear axle.
Clearance Inspection
1. Vehicle is to be fixed to a lifting rack at free
position. Refer to section 100-02.
2. Disassemble drive shaft. Refer to section 205-01.
3. Install fixture for drive gear flange.
● Fix a hard rod or tube on the tool. Clamp the other end
of the hard rod or tube on carriage or car body ridge to
prevent the movement of rear axle gear shaft flange.

4. Lower the vehicle. Let one of the rear wheels

fall on the choke to prevent the wheel from
rotating. Another rear wheel is used to measure
the total clearance of the rear axle.
5. Slowly rotate the free wheel by hand until you feel
that the movement of rear drive axle is restrained.
Using crayon or chalk, mark at a place at tire
side, 305 mm away from the wheel center.
6. Place the crayon or chalk against the tire.
Slowly turn the wheels in the opposite direction
until you feel that the movement of rear drive
axle is restrained again.

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205-00-9 Drive Shaft System – General Information
Diagnosis and Testing
Symptom List
Symptom Possible Cause
Lubricant leaking ● Vent
from gear oil seal or ● Oil seal Contact area of drive gear
semiaxis seal flange or oil guard is damaged.
● Not enough lubricant
Scratches on
differential semiaxis
gear / drive gear
● Wrong type of lubricant, or
contaminated.
● Lubricant level is too low.
● Wrong type of lubricant or
contaminated.
● Excessive bearing preload
Axle overheating
● Excessive gear wear.
● Ring gear clearance is not correct.
To o t h d a m a g e o n
● Overloading
planet gear or ring gear
● Overloading.
Semiaxis damage
● Dislocation of semiaxis tube.
2011 Boomday & Boarding Workshop manual
205-00-9
Measure
● Clean up axle housing vents.
● Install a new drive gear flange and
gear oil seal if damage is identified.
● Install a new gear, refer to 205-02
section.
Inject to axle up to standard.
● Install a new ring gear. Refer to
205-02 section. Clean up and re-
inject to axle per specification.
● Check lubricant level. Inject to axle
per specification.
● Check axle for damage. Repair if
necessary. Clean up and re-inject
to axle up to specification.
● Check the primary driven gear for
damage. Check the primary driven
Gears for wear type. Adjust preload
if necessary.
● Check all of the axle ring gear for
wear or damage Bad. Install new
parts if necessary.
● Check ring gear for scratch. Check
driven gear for wear type. Adjust
ring gear gap if necessary.
● Install a new planet gear and ring
gear. Refer to section 205-02.
● Install a new semiaxis by referring
to section 205-02.
● Check axle for damage. Check the
semiaxis tube, position and install a
new semiaxis by referring to section
205-02.
205-00-10 Drive Shaft System – General Information 205-00-10
Diagnosis and Testing

Component Test drive shaft and mark it again to an alignment

if these marks apart from each other for more
Transmission System Vibration than 1/4 circle. Check numbering marks
ATTENTION: Vibration analysis can of drive shaft to gear box tail shaft for an
be performed by using vibration alignment.
analyzer under following manufacturer After all the corrections being made, re-
instructions. examine the vibration with a speed at which
Transmission system vibration is characterized symptom occur. Reinstall the wheel and do
by higher frequency and lower amplitude than the road test again if vibration disappears. If
that of high speed driving vibration. Transmission vibration persists, proceed to step 4.
system vibration is associated with driving
speed, thus can be noted at different speed
range. Transmission system vibration can be
sensed through the tremor of vehicle floor
or heard through the rumbling and buzzing
noise. Transmission system vibration can
occur at all driving modes, while manifesting
different symptoms depending on vehicle is in
accelerating, decelerating, floating or sliding.
Check the angle of transmission system if the
vibration is particularly evident in the process of
acceleration or deceleration, especially in the low
speed. Drive shaft vibration can be simulated by
raising axle with a lifting frame or jack stand and 4. Lift the vehicle to lifting frame and disassemble
applying slight brake to imitate road resistance. the wheel. Rotate the drive shaft by rotating
1. To elevate vehicle immediately after road tests. axle. Measure the front, middle and rear
Use double-column lifting frame or jack stands deflection of drive shaft with a meter. A new
to prevent tires spots on ground. Gear into shaft shall be installed if the front and the
power train, accelerate the speed to road test central deflection exceed 0.89mm. Mark the
observation value to identify the occurrence of highest point of rear deflection if front and
vibration. If vibration is not very evident, check central deflections are within the range while
the non-driving wheel with balancer to exclude the rear is in excess, and proceed to step 5. If
imbalance as reason leading to vibration. If any point of rear deflection is in range, proceed
to step 7.
necessary, balance the non-driving wheels,
perform road test again. If the vibration is still
evident, proceed to step 2.
2. Mark the position of driving wheel to wheel nut.
Remove the wheel, install all wheel nuts in the
opposite position. Repeat road acceleration
driving. If the vibration disappears, refer to
204-04 section for tires and wheels sliding
process. If the vibration continues, proceed to
step 3.
3. Check drive shaft for evidence of physical
damage, balance sheets, coating, wrong
location, wear and signs of cardan joint locking.
Clean drive shaft and install a new cardan 5. ATTENTION: Check cardan joints when
joint. Replace the shaft if damaged. Inspect changing mark.
the numbering mark (paint points) of rear drive
Install a new cardan joint if the joint is stiff or
shaft and the axle gear flange. Disassemble
graveled.

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205-00-11 Drive Shaft System – General Information 205-00-11
Diagnosis and Testing

Make parallel markings on drive shaft and axle When replacing axle drive gear flange, the
drive gear flange. Disconnect drive shaft, rotate shaft deflection must be more than 0.89 mm.
When deflection is in the range, re-examine
for half circle, and connect it again. The drive
the vibration at road speed. Balance drive shaft
gear flange of circular axle can be rotated to
if vibration persists.
1/4 increment for fine and balanced deflection
condition. The drive gear flanges of semicircle 7. Place two hose clamps at rear position to
are confined to two positions. Check drive shaft balance drive shaft. The position of clamp
rear for deflection. Mark the highest point when head depends on the results of repeated
exceed 0.89mm, proceed to step 6. Check experiments.
for vibration at road speed if deflection does 8. Mark the rear of drive shaft into about four
not exceed. If vibration persists, perform road equal parts. Mark 1 to 4. Place a hose clamp
test by changing gear box output drive shaft at No. 1 position on drive shaft.
expansion coupling for 1 /2 circle. If vibration
persists, proceed to step 7.
6. Excessive deflection of drive shaft can be
attributed to shaft itself or axle drive gear
flange. To judge by comparing the two highest
points marked in step 4 and step 5.
A shaft must be installed for new road test if
mark location is close within 25mm.

Check vibration at road speed. Re-examine

every clamp on other position, find out the
location shown minimal vibration. If same
increase is displayed by two adjacent locations,
place the clamp head in between.
9. If the vibration persists, place a second clamp
at the same location, re-examine for vibration.

If marks are in opposite sides of drive shaft,

then expansion joint or axle drive gear flange is
the reason of vibration.

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205-00-12 Drive Shaft System – General Information 205-00-12
Diagnosis and Testing

If vibration has not been significantly improved,

rotate the clamp in the opposite direction, to
the same distance from the optimum position
as determined in step 8. Separate clamp head
for about 13mm, re-examine vibration it at road
speed.

Repeat the process of increase separation,

until a better combination, or reduce vibration
to an acceptable level.
10. Install a wheel and perform road test (apparent
vibrations on lifting frame could be not
obvious in road test).Install a new axle drive
system to absorb vibration if vibration is still
not acceptable. Refer to section 205-02A
if vibration is still unacceptable, check
the differential housing and ring gear for
deflection.
Drive Shaft Vibration
1. Perform vehicle road test to determine the key
points of vibration. Record road drive speed,
engine revolutions per minute, and the position
of gear change lever at every occurrence of
vibration.
2. Stop the vehicle, set gear box at free position.
Start engine at the critical speed determined in
Step 1.
3. Balance the drive shaft if no vibration is
sensed. Refer to vibration of power train of this
section.

2011 Boomday & Boarding Workshop manual