Failed DC shaft.

[Drover]

Bought a new custom built DC Shaft a couple of weeks before setting off for the Cape.

To cut a long story short as possible I had a Bailey Morris DC shaft that after chook73 failure was replaced with the new unit.

Well.......after completing the Creb and then OTL the DC joint collapsed at Cohen.

Been stuck ( could be worse:D) in Cairns since last Thursday, Cummins Truck Engines machine shop are doing the repairs but they need a transfer case flange to suit a D2 (front).

I ordered a new one but it hasn't turned up, so if anyone has one in Cairns would love lend for a few hours so the machine shop can drill the new DC joint to suit.

Cheers

[Pedro_The_Swift]

Drover,,
You could post this in the D2 Forum and in Gen,,

and I'll keep my fellow Mods under control till tomorrow;)

[newhue]

sorry to hear that Drover, hope that was the only dilemma of a great trip.

[Drover]

Hey Jason,

PUMA has been a gem, can't fault it. Fully loaded with the rack and still pulling 11L /100k's. Can't blame the D'fer for the shaft issues.

Very few vehicles are making it through Nolan's, watched 4 drown while we were there, apparently no big issue for D'fer:D

It hasn't wrecked the trip, we did all of the cape that we wanted before the shaft failed and as soon as it is fixed we are heading over to Catherine and then Mataranka, back through MtIsa and home.

The DC failed due to over flex of the static angle, so....it was doomed from the start.

The new one has a 32 degre flex and 1350uni's.....fingers crossed.

[Drover]

Bought a new custom built DC Shaft a couple of weeks before setting off for the Cape.

To cut a long story short as possible I had a Bailey Morris DC shaft that after chook73 failure was replaced with the new unit.

Well.......after completing the Creb and then OTL the DC joint collapsed at Cohen.

Been stuck ( could be worse) in Cairns since last Thursday, Cummins Truck Engines machine shop are doing the repairs but they need a transfer case flange to suit a D2 (front) to drill the new DC joint.

I ordered a new one but it hasn't turned up, so if anyone has one in Cairns would love a lend for a few hours so the machine shop can drill the new DC joint to suit.

The DC joint failed due to an over flex of the available static angle, the new has a 32 degre available angle and 1350uni's....so it should do the job but only time will tell.

Cheers
Grant


Cheers

[Nera Donna]

Good luck Drover, hope it all works out and you get back on the road ASAP

[V8Ian]

Try Hypertune in Hartly St, walking distance from Cummins, 100 yards from Aumuller St.

[steveG]

If you're just after dimensions for drilling the holes in the flange, there is a drawing on Tom Woods driveshafts site. Go to the Landrover section from the link on this page:
Tom Wood's Custom Drive Shafts - Tom Woods Custom Drive Shafts Custom Driveshafts Specialist (http://www.4xshaft.com/)

Steve

[Drover]

The Machine shop want the flange to ensure the holes are centered and correctly spaced, there is no room for slightest error.

They still have the old shaft but even this is not precise enough.

Cheers

[LowRanger]

Bought a new custom built DC Shaft a couple of weeks before setting off for the Cape.

To cut a long story short as possible I had a Bailey Morris DC shaft that after chook73 failure was replaced with the new unit.

Well.......after completing the Creb and then OTL the DC joint collapsed at Cohen.

Been stuck ( could be worse:D) in Cairns since last Thursday, Cummins Truck Engines machine shop are doing the repairs but they need a transfer case flange to suit a D2 (front).

I ordered a new one but it hasn't turned up, so if anyone has one in Cairns would love lend for a few hours so the machine shop can drill the new DC joint to suit.

Cheers

Grant

So if I am reading this correctly,it is the new Gibson shaft that has failed,and not the Bailey Morris shaft,is this correct?
Hope the new shaft does the job either way!!!
And hope that Iain reads this also:eek:

[rick130]

The TW shaft still holding up OK Wayne ?

I'm about to order one. ;)

[SVX37]

Hi Grant - all the best with the next new DC shaft. Were you towing your Camper Trailer through the Cape? Did you get through firdst go through Nolan's?

Nigel

[LowRanger]

The TW shaft still holding up OK Wayne ?

I'm about to order one. ;)

Rick
The TW shaft is going great!!!
You won't regret it

[dullbird]

Grant

So if I am reading this correctly,it is the new Gibson shaft that has failed,and not the Bailey Morris shaft,is this correct?
Hope the new shaft does the job either way!!!
And hope that Iain reads this also:eek:

Yes I'm trying to work that out as well..

and Drover what do you mean over flex of the static angle?

[Drover]

Yeah, the bullet proof Gibson.

Now that I "nearly" know everything about front DC joints prop shaft I can talk the talk.....

Static angle refers to the maximum angle that the joint can operate at. Over flexing is just that. In other words the angle that the shaft needed to turn at was not enough to deal with actual angle between the TC and front diff at full flex.

The new DC joint is a 32 degre static joint with 1350 uni's, more than enough.

Gibson's have been really good about it and are covering all repairs here Cairns. In fareness to Gibsons it likely to be a consequence of making a shaft For specific use with out ever seeing the vehicle it was being fitted to.

And I have been in touch with Iain and Gibsons will make necessary alteration to Iain's once it is all sorted.

At least it's hot here at Cairns.

[Drover]

Hi Grant - all the best with the next new DC shaft. Were you towing your Camper Trailer through the Cape? Did you get through firdst go through Nolan's?

Nigel

Hey Nigel, no camper just the OzTent.

Yeah first go at Nolan's, thank goodness there is no second chance, it is very deep this year.

Air down to 12psi, fitted up water blind and happy days.

Cheers

[dullbird]

Yeah, the bullet proof Gibson.

Now that I "nearly" know everything about front DC joints prop shaft I can talk the talk.....

Static angle refers to the maximum angle that the joint can operate at. Over flexing is just that. In other words the angle that the shaft needed to turn at was not enough to deal with actual angle between the TC and front diff at full flex.

The new DC joint is a 32 degre static joint with 1350 uni's, more than enough.


Gibson's have been really good about it and are covering all repairs here Cairns. In fareness to Gibsons it likely to be a consequence of making a shaft For specific use with out ever seeing the vehicle it was being fitted to.

And I have been in touch with Iain and Gibsons will make necessary alteration to Iain's once it is all sorted.

At least it's hot here at Cairns.

Now that is what II call customer service

[cal415]

Wow sorry to hear about that, im supprised it has failed, did you contact gibsons yet? Why do you think it was caused but being overflexed?

[dullbird]

yep cal sounds like Gibson are being really good about it have a look in the defender section..

Sounds like they got great customer service

[d2dave]

Very lucky it did not happen at speed. dmdigital had his let go at speed and it caused $10K damage.

[cal415]

Good to hear gibsons is sorting it out, but I'm supprised it failed, I know he used a different dc in yours to what I have in mine. I am going past to see them shortly so I will have to find out what he is swapping it to, he has my standard front shaft at the moment is modifying the TC end to allow greater angle and d2 bolt pattern without a dc so I can have it as a spare

[Pedro_The_Swift]

Threads merged Drover,,
Hope everything worked out--

[Drover]

Good to hear gibsons is sorting it out, but I'm supprised it failed, I know he used a different dc in yours to what I have in mine. I am going past to see them shortly so I will have to find out what he is swapping it to, he has my standard front shaft at the moment is modifying the TC end to allow greater angle and d2 bolt pattern without a dc so I can have it as a spare

Hey Mick, I am going to the same joint as yours (I think), it is the 32deg with 1350 uni's and sealed Cente joint.

It is listed as the heavy duty - wide angle replacement for the CVK2a (the one that failed).

Chris is upset that the problem even occurred, but can't fault his reply to the issue.

Cheers

[chook73]

Sounds like a much better response than I got from bm but sorry to hear that it happened. I can certainly sympathize with your situation grant.

I haven't fitted mine yet so once it's all sorted out I will arrange with gibsons to get it fixed up and hopefully that will be the end of it all.


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[Drover]

Picked up the new "improved" DC shaft, complete with Cummins sticker, today.

It looks great, but I have fallen for that mistake before :(

It now runs the same DC joint as Mick's (cal415), it has more static angle and bigger uni's.

I have test run it, only up to 80k's, smooth as but only time will tell how long it will last.

Leaving Cairns for Normanton in the morning. Then onto Mataranka, have had to miss a couple of stops due to the delay with the shaft.

Cheers.

[chook73]

Hope all goes well for you. I can highly recommend lorella springs it's well worth pulling in there.


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[cal415]

Good to hear your back on the road, when your back down this way you might want to give you old shaft to gibsons to modify like he is doing for mine and keep it as a spare for trips like this. Mine is getting just one end changed to a deeper flange to allow more angle and drilled for d2 flange pattern, keeping it simple uni to uni. its probobly not going to be ideal but it wont bind and will make a good spare.

[Drover]

Good to hear your back on the road, when your back down this way you might want to give you old shaft to gibsons to modify like he is doing for mine and keep it as a spare for trips like this. Mine is getting just one end changed to a deeper flange to allow more angle and drilled for d2 flange pattern, keeping it simple uni to uni. its probobly not going to be ideal but it wont bind and will make a good spare.

Best idea I have heard in a week !

I have to go and see Chris when I get home to drop off the busted DC joint for him to look at and work out the $$$$.

I'll take my old shaft up with me and get the same done as what you are getting.

Thanks Mick for he idea.

New shaft seem good, put 750k's on it today from Cairns to Normanton, nice and smooth, no vibration.

Other than the shaft the PUMA just continues to impress, these really are great trucks.

Cheers

[chook73]

Hey drover pleased to hear it held up ok for you yesterday should I be giving gibsons a call?


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[Drover]

Hey Iain,

It probably wouldn't hurt, but Chris wants to look at my failed joint to make his own determination on exactly what caused the failure. He is not convinced of the over flex diagnosis from Cummin's Cairns & maintains his opinion of the strength and quality of the CVK2a.

Have a chat with him, he is very reasonable man, but will likely want to look at mine before any decisions are made.

Cheers.

[chook73]

No problems it's still off the road at the moment for another 6 weeks anyway so there is no rush. I will wait until your back and they can have a good look at it.

Safe travels and I hope it all holds up for you.


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