Front Drive Shaft Update

[Mountain4x4]

Mine was those small lift springs and warranty denied with out even a thought to it. What would it matter, just be waiting around for another failure.

 

[ECrider]

I think @landmannnn 's idea of a strop/bracket bolted onto the sub frame has got to be good insurance until a fix is found. Then you can hopefully limit the damage and swap out the trashed joint for a replacement and continue on. If you have spares but the sodding thing has knocked the sh1te out of your gearbox and anything else within reach it doesn't help much. Would also perhaps help save human damage as well. Any engineers here want to make a killing on the forum shop, hell, I'd buy two!!!

 

[Logsplitter]

I think @landmannnn 's idea of a strop/bracket bolted onto the sub frame has got to be good insurance until a fix is found. Then you can hopefully limit the damage and swap out the trashed joint for a replacement and continue on. If you have spares but the sodding thing has knocked the sh1te out of your gearbox and anything else within reach it doesn't help much. Would also perhaps help save human damage as well. Any engineers here want to make a killing on the forum shop, hell, I'd buy two!!!

Hey mate I’m meeting an engineer/designer and Saturday and will discuss this along with other ideas.

 

[landmannnn]

I think @landmannnn 's idea of a strop/bracket bolted onto the sub frame has got to be good insurance until a fix is found. Then you can hopefully limit the damage and swap out the trashed joint for a replacement and continue on. If you have spares but the sodding thing has knocked the sh1te out of your gearbox and anything else within reach it doesn't help much. Would also perhaps help save human damage as well. Any engineers here want to make a killing on the forum shop, hell, I'd buy two!!!

I'm in the process of fabricating one. Actually not really in the process, just looked at the shaft and looked at some metal.

Will post a few pictures this week.

 

[C-Mack]

Others have mentioned a driveshaft protection loop/hoop offering some level of containment should a catastrophic failure occur. How about a loop which simultaneously holds the Bowden cable out of the way and constrains the driveshaft should it fail? Seems like Agile’s Bowden cable bracket solution is almost halfway there… it would have to be a considerably more stout version of it though.

 

[Ovrland Bill]

In the last 20 years of 4wding I have always wanted and modified vehicles to get more flex not less
Seems not fit for purpose to me

Nevertheless, if “push comes to shove”, I will trade ‘performance’ for ‘reliability’.

 

[Ovrland Bill]

Pretty definitive. We are just not seeing the high temps some thought. The joints do get pretty hot when fresh and new, but clearly they stabilize after break in.

I'm sticking with the boots extruding/pinching themselves at full or close to full suspension extension.

Slap a pair of limit straps about 1" shorter than the stock shocks and I bet you could go merrily down the road for an extremely long time.

Won't be as great off road but at least it's not going to blow up.

This is the best “intermediate fix” I have heard of.

 

[ORSO]

This is the best “intermediate fix” I have heard of.

I also believe it is the only viable route if you want to mount more performing shock absorbers such as Fox or King as they are all longer than the original ones.

 

[ORSO]

I think one possible solution to the problem of the shaft coming out of the CV joint is to replace the C-clip with a bolt like the one I posted earlier.
Why delegate such a risky and hard work to a C-clip?

 

[ECrider]

I think one possible solution to the problem of the shaft coming out of the CV joint is to replace the C-clip with a bolt like the one I posted earlier.
Why delegate such a risky and hard work to a C-clip?

I'd prefer something more beefy than a circlip. We should not have to need it but clearly do at ghe mo!

 

[Zimm]

the c-clip shouldn't be an issue. I'm wondering why it is. People that have had the c-clip fail, actually found it, right? As in, it was there to begin with.

 

[ORSO]

yes there was

 

[pmatusov]

I think one possible solution to the problem of the shaft coming out of the CV joint is to replace the C-clip with a bolt like the one I posted earlier.
Why delegate such a risky and hard work to a C-clip?

The photo you posted is of an axleshaft. It still uses C-clips in both CV joints, and the "bolt" is the attachment to the hub.

 

[C-Mack]

A retention bolt instead of a c-clip would certainly work better and last longer between failures but the core issue still remains. No matter what retention method is used the overall design of the front end is still allowing the impacts to it to take place. Given enough whacks the head of a retention bolt would eventually crack and fatigue as well I would think.

 

[ORSO]

The photo you posted is of an axleshaft. It still uses C-clips in both CV joints, and the "bolt" is the attachment to the hub.

Yes, it was an example. But the first time I disassembled my CV joint, I actually thought a screw would be safer than a clip. In fact, a few kilometers later, it came loose...
The problem is the limited space between the end of the shaft and the flange, but I think it can be solved by redesigning the shaft or even modifying the existing one.

 

[ORSO]

A retention bolt instead of a c-clip would certainly work better and last longer between failures but the core issue still remains. No matter what retention method is used the overall design of the front end is still allowing the impacts to it to take place. Given enough whacks the head of a retention bolt would eventually crack and fatigue as well I would think.

we should engineer the thing to size everything

 

[landmannnn]

Others have mentioned a driveshaft protection loop/hoop offering some level of containment should a catastrophic failure occur. How about a loop which simultaneously holds the Bowden cable out of the way and constrains the driveshaft should it fail? Seems like Agile’s Bowden cable bracket solution is almost halfway there… it would have to be a considerably more stout version of it though.

Just what I am planning on my little fabrication project

 

[C-Mack]

Just what I am planning on my little fabrication project

Nice!!! Share with the group once you get it all engineered out. If we can’t have a long lasting driveshaft fix for failing clips or boots at least we can possibly have some safety retention in place.

 

[Clark Kent]

What's everybody's thoughts about fitting a driveshaft retaining/safety loop?

They seem to be widely available often as a "universal" kit.
The position of the transmission cross member wouldn't make a difficult fit.

Just a random picture

View attachment 7913682

Well I think it's a great idea

Post in thread 'Front Driveshaft CV redesign'
https://www.theineosforum.com/threads/front-driveshaft-cv-redesign.12419230/post-1333365767

 

[NQ94]

Something like the C clip used on early Chevy 10 bolt or early Toyota diffs that held the drive axles and bearings in the housing at the diff would be a solution for the circlip. There is a lot more force put on c clip from an axle then a drive shaft would ever produce.