Opel Insignia: Description and Operation

PROPELLER SHAFT DESCRIPTION AND OPERATION

The function of the propeller shaft is to transfer power from the power transfer unit to the differential clutch. It consists of three tubes sections; the front tube contains a constant velocity fixed joint mating to the PTU and a constant velocity plunging joint in the rear of the tube, the middle tube contains one universal joint (Cardan or Polhem joints) at the end, and the rear tube contains a constant velocity fixed joint. The front propeller shaft's support bearing is fitted by the plunging joint and the rear propeller shaft's support bearing is fitted by the universal joint. The bearings are mounted in rubber bushings which are fitted in brackets, and these in turn are bolted to the underside of the vehicle. The position of the brackets is very precisely measured during vehicle manufacture. The propeller shaft does not run in a straight line between the power transfer unit and the differential clutch but is instead gently curved, and this is to avoid vibration.

Front Drive Shaft

The propeller shaft connects into the power transfer unit pinion with a female spline. The function of the joint is to handle the difference in angle between pinion and propeller shaft, as well as to be flexible longitudinally.

Support Bearings

Directly after the plunging joint/u joint are the propeller shaft's support bearings, which are the single-row, permanently-lubricated groove ball bearing type. They are fitted in rubber bushings which in turn are fitted in brackets.

The brackets are bolted to the underside of the vehicle and their position is very precisely measured during vehicle manufacture. If the support bearing brackets are fitted incorrectly then vibration will occur.

Rear Drive Shaft

The propeller shaft connects to the differential clutch driver by means of the rear drive shaft constant velocity fixed joint which is plugged into the driver.

The function of the joint is to handle the difference in angle between differential clutch driver and propeller shaft, as well as to be flexible longitudinally. The rear drive shaft universal joint is also a CV joint and is friction welded to the rear pipe section and constitutes one unit together with the propeller shaft.

Front/Rear Drive Shaft Universal Joint (CV/Rzeppa Joint)

The CV/Rzeppa joint consists of an outer bearing race, which also constitutes the joint's housing. On its inside are 8 semi-spherical grooves. The inner bearing race consists of a cylindrical section, in the periphery of which are 8 semispherical grooves. The inner bearing race is fitted inside the outer one and there are 8 steel balls between the grooves. A ball holder is fitted between the outer and inner bearing races. There are steel balls between the bearing races which transfer the movement between outer and inner bearing races.

Center Joints (Universal/Polhem Joint)

There is one universal/Polhem joint fitted between center and rear pipe sections. The function is to handle the angle difference between pipe sections. The joint is angled less than 1.5 degrees in relation to each other to avoid vibration.

The universal/Polhem joint consists of two forks, produced in forged steel which grip a cross by means of arms. The pins of the cross are mounted in needle bearings in the forks' bearing sleeves. The sleeves are permanently locked in the forks by means of compressive strain.

The bearing sleeves are permanently lubricated with synthetic special grease which contains molybdenum disulphide.

The drive shaft universal joint is friction welded to the relevant pipe section and constitutes one unit together with the propeller shaft.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

DT-51329

Drive Shaft Remover

GE-2619-A

J-2619-A

Slide Hammer

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