Front Drive Shaft Update

[MileHigh]

Late to the discussion, but to summarize, it looks like there is at least one commercial replacement version- though it is early days and there are known vibration issues inherent with the design.

So, looking forward:

1: It seems that a double cardan would address the potential issues with the current alternative? Is that overkill, especially for an unlifted truck?

2. While I don’t want to have a front drive shaft fail, I also don’t want to spend a few grand on something that might be handled under warranty (maybe).

3. Is there an inspection regime that would catch if the current set-up is going to fail?

Is that pretty good summary or where we are on the path forward.

 

[TCMColorado]

Late to the discussion, but to summarize, it looks like there is at least one commercial replacement version- though it is early days and there are known vibration issues inherent with the design.

So, looking forward:

1: It seems that a double cardan would address the potential issues with the current alternative? Is that overkill, especially for an unlifted truck?

2. While I don’t want to have a front drive shaft fail, I also don’t want to spend a few grand on something that might be handled under warranty (maybe).

3. Is there an inspection regime that would catch if the current set-up is going to fail?

Is that pretty good summary or where we are on the path forward.

1. A double cardan at the transfer case plus retention of a Rzeppa CV at the pinion is a potential solution. A twin double cardan is not, it will vibrate. A double cardan in combination with a single u-joint is not, it will vibrate.

2. No replacement shaft will be handled under warranty.

3. Regular inspection of the CVs will identify cracking early enough to prevent full failure of the CV joint. At first they will simply start to loose grease at which point they get replaced before joint failure that results from complete loss of lubrication.

 

[pmatusov]

3. Is there an inspection regime that would catch if the current set-up is going to fail?

When I noticed spiderweb of small cracks in my front driveshaft's boots, I was checking them every gas tank, give or take some.

 

[Shopkeep]

1. A double cardan at the transfer case plus retention of a Rzeppa CV at the pinion is a potential solution. A twin double cardan is not. A double cardan in combination with a single u-joint is not.

2. No replacement shaft will be handled under warranty.

3. Regular inspection of the CVs will identify cracking early enough to prevent full failure of the CV joint. At first they will simply start to loose grease at which point they get replaced before joint failure that results from complete loss of lubrication.

2.??? If you run stock suspension and your shaft goes it will be handled under warranty.
(Or do you mean if you fit an aftermarket shaft you will have no warranty?).

While I love the amount of passion in this thread the vast majority of owners with stock suspension are not having issues, some have traversed North and South America from top to bottom and others have gone well beyond 100,000kms without issue.

 

[TCMColorado]

(Or do you mean if you fit an aftermarket shaft you will have no warranty?).

Yes, that is what I meant.

And if you have a factory shaft and lift the vehicle then warranty coverage appears to depend on the dealer. Some are honoring the warranty and some are not.

 

[TCMColorado]

While I love the amount of passion in this thread the vast majority of owners with stock suspension are not having issues, some have traversed North and South America from top to bottom and others have gone well beyond 100,000kms without issue.

Indeed if the suspension is at stock height the issue of CV failure is considerably reduced but not eliminated. In particular heavy towing and long distances at very high speeds (US Interstates for example) contribute to the problem. The issue with towing is not the weight but that towing can force the suspension into the extreme end range of motion which then damages the CV boots.

 

[Lexx]

Some folks have slightly larger diameter tires than stock, while NOT having a lift. Will these folks have an issue with warranty service for their CV boots if there's a problem? AFAIK a larger tire diameter does not affect the driveshaft angles.

 

[HeavyFoot]

Some folks have slightly larger diameter tires than stock, while NOT having a lift. Will these folks have an issue with warranty service for their CV boots if there's a problem? AFAIK a larger tire diameter does not affect the driveshaft angles.

Correct. I confirmed this with the service tech at MileOne in MD as well. The tire size in no way changes the angle of the shaft. He said lifting it will void the warranty (of the shaft), but tire size change will not.

 

[Shopkeep]

Some folks have slightly larger diameter tires than stock, while NOT having a lift. Will these folks have an issue with warranty service for their CV boots if there's a problem? AFAIK a larger tire diameter does not affect the driveshaft angles.

I believe there was an early report of someone who knew someone who heard from someone that a dealer had said it would not be covered in this case, but there has not been a confirmed rejection on this basis.

 

[TCMColorado]

Some folks have slightly larger diameter tires than stock, while NOT having a lift. Will these folks have an issue with warranty service for their CV boots if there's a problem? AFAIK a larger tire diameter does not affect the driveshaft angles.

There is not 100% agreement on this, but the general consensus is that larger tires on stock suspension is not a problem when it comes to warranty coverage for the front drive shaft.

 

[Shopkeep]

In another thread today @Diego reported the failure of his front drive shaft but the picture shows the metal collar tearing, is this a different type of failure than the boot or circlip?

 

[Shopkeep]

In another thread today @Diego reported the failure of his front drive shaft but the picture shows the metal collar tearing, is this a different type of failure than the boot or circlip?

View attachment 7920975

On looking closer is it the circlip failing and the shaft coming out of its seat, bending and deforming the collar?

 

[Dokatd]

In another thread today @Diego reported the failure of his front drive shaft but the picture shows the metal collar tearing, is this a different type of failure than the boot or circlip?

View attachment 7920975

That's a cool failure. Seems the joint cooked but maybe the boot didn't fail. Maybe poorly greased from factory.