PROPELLER SHAFTS

Introduction and Legacy Vehicles 5

Propeller ShaftsIntroduction and Legacy VehiclesPropeller Shafts - IntroductionUnlike many others, Land Rover provides grease fittings on both the universal joints and slipyokes for routine servicing.

PROPELLER SHAFT/UNIVERSAL JOINT SERVICENormal service intervals are:

Range Rover Classic, Defender 110, 1994-1995 Defender 90:Universal Joints: Every 7,500 miles (12,000 km)Slip Joints: Every 22,500 miles (36,000 km)

1994 - 1995 Discovery:Universal Joints and Slip Joints: Every 30,000 miles (48,000 km)

1995 - 2002 Range Rover, 1996 Onward Discovery, 1997 Defender 90:Universal Joints and Slip Joints: Every 15,000 miles (24,000 km)

The correct grease is NLGI-2, multipurpose lithium based grease.Failure to lubricate the sliding joints will accelerate spline wear and result in driveline “clunk”.

PROPELLER SHAFT/UNIVERSAL JOINT OVERHAULSection 47 in the appropriate Workshop Manual provides step by step procedures for inspectingand replacing prop shafts and components.When removing mark flanges so that they can be re-assembled in the original positions. Notdoing so can lead to vibrations which were not present prior to disassembly.

PROPELLER SHAFTS

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RANGE ROVER CLASSIC, DEFENDER, AND DISCOVERY SERIES IThe front propeller shaft (driveshaft) consists of a solid shaft with splined slip yoke and two setsof “Hooks” or Spicer type universal joints coupled to flanges. The driveshaft flanges are thenbolted to the front output flange of the transfer gearbox and the front diff flange, respectively.Note in the illustration that the “prop” shaft sections are intentionally out of phase. This reducesthe normal vibration tendency of a Spicer type joint operating at an angle.

The rear propeller shaft consists of a two piece tubular shaft with slip joint which is “in-phase”.Since the rear prop is longer and there is less angle between the transfer gearbox and rearaxle, normal phasing is utilized. See the illustration below. The universal joints/flanges arebolted to the rear output flange of the transfer gearbox and the rear differential pinion flange,respectively.

PROPELLER SHAFTS

Introduction and Legacy Vehicles 7

1995 RANGE ROVER CLASSIC, 1994-1996 DISCOVERY

The Spicer type rear universal joint on the rear prop is replaced with a flexible coupling onDiscovery and 1995 Range Rover Classic. Note that the rear diff flange was changed toaccommodate this type of universal joint. Due to the design, the flexible coupling requires nomaintenance. Should disassembly be required, use new special tool LRT-51-008 to remove thespigot (hub) from the diff flange. This tool replaces LRT-37-005 which was used with the slidehammer LRT-99-004 in the past.As a running change, the original style rear propeller shaft was installed on 1997 Discovery andDefender.

PROPELLER SHAFTS

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RANGE ROVER 4.0SE/4.6HSEThe Range Rover 4.0/4.6 utilizes two tubular style propeller shafts with Hooks joints at eitherend.Like Classic, Defender and Discovery, the front shaft is out of phase with the yokes out of line.When disassembling, mark the flanges for re-assembly to preserve shaft balance.

PROPELLER SHAFTS

Discovery Series II 9

PROPELLER SHAFTSDiscovery Series IIDISCOVERY SERIES II

A redesigned front propeller shaft (driveshaft) has been used on Discovery Series II . The newdriveshaft uses a double hooks type joint at the transfer box drive flange. This is best describedas a double universal joint. The double hooks type joint provides the driveshaft with increasedarticulation and reduces noise, vibration and harshness (NVH) levels. The increased degree ofarticulation was necessary due to a change to the front axle pinion angle. Service to the front driveshaft is limited to replacement of the universal joint at the front end(axle end) only. Should the universal joints fail at the double hooks joint, then the completedriveshaft will need to be replaced. The rear driveshaft is identical to 99 model year Discoveryvehicles with a rubber damper.

PROPELLER SHAFTS

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DISCOVERY SERIES II FRONT DRIVESHAFT

DISCOVERY SERIES II REAR DRIVESHAFT

PROPELLER SHAFTS

Freelander 11

Propeller ShaftsFreelanderFREELANDER DRIVE SHAFT AND PROPELLER SHAFT COMPONENT LAYOUT

1. Rear drive shaft2. Final drive unit3. Rear propeller shaft4. Viscous Coupling Unit (VCU)5. Front propeller shaft6. Intermediate Reduction Drive (IRD)7. Front drive shaft8. Gearbox

PROPELLER SHAFTS

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DRIVE SHAFT COMPONENTS

1. Outer joint2. Clamp3. Gaiter4. Clamp5. Circlip 6. Shaft7. Gaiter8. Inner joint9. Slinger - oil seal (rear driveshafts only)

10. Circlip

PROPELLER SHAFTS

Freelander 13

PROPELLER SHAFT AND VCU COMPONENTS

1. Universal joint2. Rear propeller shaft3. VCU4. Propeller shaft bearing 5. Coupling6. Front propeller shaft

PROPELLER SHAFTS

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DESCRIPTION

DRIVE/PROPELLER SHAFTS Two drive shafts transmit drive from the intermediate reduction drive (IRD) to the front wheels,and to two further drive shafts transmit drive from the final drive (differential) unit to the rearwheels. Two propeller shafts and a viscous coupling unit (VCU) transmit drive from the IRD to the finaldrive unit.

DRIVE SHAFTS All four drive shafts are of similar construction, the main differences being in their respectiveoverall lengths and the inclusion of dampers on the front drive shafts.Each drive shaft is a solid shaft with inner and outer constant velocity joints. The inner joint is ofthe tripod type with spherical bushing to reduce sliding resistance; the shaft and inner joint areone assembly. The outer joint is of the ball and socket type, with a splined connection betweenthe joint and the shaft. The joints are packed with grease and protected by gaiters.

FRONT PROPELLER SHAFT The front propeller shaft consists of a thin walled tube with a coupling welded to the front endand a conventional universal joint welded to the rear end. The coupling bolts to the outputflange of the IRD. The universal joint is splined to the input shaft of the VCU and secured by abolt and tab washer.The coupling reduces vibration and accommodates both angular movement (10 degreesmaximum) and axial movement (50 mm maximum) between the propeller shaft and the IRD.The universal joint incorporates serviceable, sealed needle bearings.

VCU The VCU automatically controls the transfer of drive to the rear wheels by limiting the speeddifferential between the front and rear propeller shafts. The unit is supported in two propellershaft bearings attached to the floor cross member.The VCU is a short cylinder which contains an input shaft supported in a roller bearing race atthe front and a ball bearing race at the rear. Within the cylinder, slotted discs are alternatelyattached to the outer surface of the input shaft and the inner surface of the cylinder. An outputshaft is welded onto the rear of the cylinder. The input shaft is attached to the front propellershaft and the output shaft is attached to the rear propeller shaft.The cylinder is a sealed unit filled with a silicon jelly. The viscosity of the silicon jelly increaseswhen subjected to shear. When there is a speed differential between the front and rearpropeller shafts, adjacent slotted discs in the VCU rotate in relation to each other. The shearingaction of the rotating slotted discs increases the viscosity and resistance to rotation of thesilicon jelly.

PROPELLER SHAFTS

Freelander 15

1. Cylinder2. Slotted discs3. Input shaft

4. Roller bearing 5. Ball bearing6. Output shaft

The rear wheels are 0.8% under driven, so in most conditions the vehicle is effectively frontwheel drive, with the rear wheels turning the rear propeller shaft slightly faster than the IRDdrives the front propeller shaft. Since the speed differential is low, the increase in viscosity ofthe silicon jelly is marginal and there is little resistance to relative rotation of the slotted discs.When there is a significant speed differential between the front and rear propeller shafts, e.g.when the front wheels lose traction or when traversing rough terrain, the viscosity andresistance to rotation of the silicon jelly increases to a level that slows or stops relative rotationof the slotted discs. With the front and rear propeller shafts locked together, drive is thustransferred from the IRD to the rear wheels.

Propeller Shaft BearingsThe two propeller shaft bearings are identical, and each consist of a roller bearing racemounted into a centre bearing housing. The bearing is sealed-for-life and is a press fit on theinput/output shaft of the VCU. Bearing covers and slingers prevent the ingress of moisture.

REAR PROPELLER SHAFTThe rear propeller shaft consists of a thin walled tube with a conventional universal joint weldedto each end. The rear universal joint is bolted to the input flange of the final drive unit. The frontuniversal joint is splined to the output shaft of the viscous coupling unit and secured by a boltand tab washer. Both universal joints incorporate serviceable, sealed needle bearings.

PROPELLER SHAFTS

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NOTES

PROPELLER SHAFTS

New Range Rover 17

Propeller ShaftsNew Range RoverNEW RANGE ROVER DRIVE AND PROPELLER SHAFTS COMPONENT LOCATION

1. Front RH drive shaft2. Mounting bracket3. Engine sump4. Transfer box5. Rear propeller shaft assembly6. Rear RH drive shaft7. Rear differential8. Rear LH drive shaft9. Support bearing

10. Front propeller shaft11. Front LH drive shaft12. Front differential

PROPELLER SHAFTS

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NEW RANGE ROVER DRIVE AND PROPELLER SHAFTS

GENERALThe front drive shafts are handed components with the RH drive shaft being longer than the LHdrive shaft. Both shafts are of similar construction with constant velocity (CV) joints at each endto allow for steering and suspension movement.The rear drive shafts are identical with a CV joint at each end to allow for suspensionmovement.Propeller shafts are used to transmit drive from the transfer box to the front and reardifferentials.The front propeller shaft is a one piece unit, connected to the transfer box by a flexible rubbercoupling and mating with the front differential unit via a splined shaft.The rear propeller shaft is a two piece unit, supported on a central bearing due to its increasedlength. The propeller shaft is connected to the transfer box and the rear differential with CVjoints. A universal joint allows for the angular deviations of the propeller shaft due toacceleration and braking.

FRONT DRIVE SHAFTSThe front drive shafts are similar in their construction. The only difference is the lengths of eachshaft. The LH drive shaft has a total length of 677 mm. The RH drive shaft is a longer shaftwhich passes through a housing and the engine sump to the differential and has a total lengthof 1024 mm.

PROPELLER SHAFTS

New Range Rover 19

LH drive shaft shown, RH drive shaft similar

1. Snap ring (3 off)2. Drive shaft3. Outer CV joint4. Stake nut5. Inner CV joint

The outer CV joint has a target on the outer diameter. This is used by the ABS wheel speedsensor for vehicle and wheel speed calculations. Refer to the Braking section for further details.Each drive shaft consists of two CV joints and gaiters, an outer tube, a solid shaft and a ballcage assembly.

PROPELLER SHAFTS

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Front Drive Shaft – Sectional View

LH drive shaft shown, RH drive shaft similar

1. Outer CV joint2. Clamp3. Outer tube4. Sealing plug5. Ball cage6. Shaft7. Inner CV joint8. Snap ring – differential9. Snap ring

10. Gaiter11. ABS sensor target ring

910109

M47 0439

1 87262542 32

11

PROPELLER SHAFTS

New Range Rover 21

The CV joints are of the Birfield design. This design uses longitudinal, elliptical grooves whichretain six steel balls. The balls are further retained by a cage. The constant velocity is achievedby the position of the steel balls. If a centre line is drawn through the balls and the driven hub ordifferential shaft, the two centre lines always bisect each other at the angle of drive. Thiscondition allows the rotational speed of the driven shaft to be passed to the driven hub ordifferential shaft with no loss of rotational speed regardless of the shaft angle. The CV joints arepacked with grease which is retained in the joint by a synthetic rubber gaiter. The gaiter isretained at each end by a metal clamp which provides a water tight seal to prevent the ingressof dirt and moisture. The CV joints are retained on their respective shaft or tube by an internalsnap ring. The snap rings are located in a groove on each shaft or tube end and locate in amating groove in the CV joint. The CV joints can be removed by a sharp tap with a soft mallet onthe CV joint housing which releases the snap ring from the groove.The shaft is a sliding fit inside the outer tube which allows for the small length changes whichoccur with articulation of the suspension. The shaft is located in a ball cage which is retainedinside the outer tube. The ball cage ensures that the shaft is held rigidly in the outer tube whileallowing it to freely move in and out of the tube as necessary. A sealing plug is pressed into theouter tube and retains grease around the balls in the cage.The inner CV joint shaft is splined and mates with splines in the front differential. A snap ring islocated around the inner shaft and, when fitted in the differential, locates in a mating groove inthe differential splined bore. The CV joint shaft is removed from the differential in a similarmanner as removing a CV joint.

PROPELLER SHAFTS

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REAR DRIVE SHAFTS

1. Drive shaft2. Outer CV joint3. Stake nut4. Snap ring (2 off)5. Bolt M12 (6 off)6. Shim (3 off)7. Inner CV joint

The rear drive shafts are identical in their construction. Each drive shaft has a total length of 687mm. The inner CV joint has six holes for attachment with bolts to the differential output flange.Each pair of bolts is fitted with shim which secures the bolts after tightening.The outer CV joint has a target on the outer diameter. This is used by the ABS wheel speedsensor for vehicle and wheel speed calculations. Refer to the Braking section for further details.Each drive shaft consists of two CV joints and gaiters and a tubular shaft.

PROPELLER SHAFTS

New Range Rover 23

Rear Drive Shaft – Sectional View

1. End cap2. Inner CV joint3. Circlip4. Gaiter5. Tube6. Outer CV joint7. ABS Sensor target ring8. Snap ring9. Clamp

10. Circlip

The CV joints used on the rear drive shafts are of the Birfield design. Refer to the Front DriveShafts for a description of the CV joints.The outer CV joint is retained on the tube by an internal snap ring. The CV joint can be removedby a sharp tap with a soft mallet on the CV joint housing which releases the snap ring from thegroove. The inner CV joint is retained on the shaft by two circlips. This CV joint is different indesign to the outer CV joint but the operating principle is the same. An end cap is pressed overthe inner end of the CV joint to prevent the ingress of dirt and moisture. Both CV joints are fittedwith gaiters which are secured with metal clamps.

7

M47 0441

9 8999

42 31 5 64

10

PROPELLER SHAFTS

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FRONT PROPELLER SHAFT

1. Front propeller shaft2. Nut M12 (6 off)3. Coupling adaptor4. Coupling5. Bolt M12 (6 off)6. Seal

The front propeller shaft is constructed from 2.1 mm wall tubular steel. A three arm coupling iswelded at one end. The opposite end has a splined shaft welded to the tube. The shaft has anoverall length of 752 mm.The three arm coupling has three holes which allow for attachment to the coupling and thecoupling adaptor. The coupling adaptor and the coupling are secured to the shaft with threebolts and nuts. The flexible coupling attaches to the front output shaft of the transfer box and issecured with bolts in the three remaining holes in the coupling.

PROPELLER SHAFTS

New Range Rover 25

The coupling is a rubber moulding. The coupling is designed to transfer rotational drive from thetransfer box to the front propeller shaft without wind-up, but simultaneously compensating forsmall amounts of misalignment and absorbing torque and vibrational loading. Each of the sixattachment holes is lined with a metal bush. The bush is required to prevent compression of thecoupling by the attachment bolts and nuts.The splined shaft has 42 splines which mate with corresponding splines in the input shaft of thefront differential. A shroud is pressed over the splined shaft. The shroud seals against an O-ringseal on the front differential input shaft, preventing the ingress of dirt and moisture. The splinesallow for movement of the propeller shaft caused by small movements in the transmission andtransfer box mountings.

PROPELLER SHAFTS

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REAR PROPELLER SHAFT

1. Washer2. Bolt M123. Propeller shaft - Front4. Stud (6 off)5. Shim (3 off)6. Nut (6 off)7. Nut (2 off)8. Shaft bearing assembly

9. Propeller shaft - Rear10. Bolt M12 (6 off)11. Shim (3 off)

PROPELLER SHAFTS

New Range Rover 27

The rear propeller shaft assembly consists of front and rear shaft assemblies and a centrallymounted shaft bearing. The rear propeller shaft assembly has an overall length of 1280 mm.

Front Shaft AssemblyThe front shaft assembly consists of a CV joint at the front and a splined shaft at the rear. Thefront shaft consists of a tube with welded, splined shafts at each end.The forward splined shaft accepts the CV joint which is secured with a circlip. The CV joint ispacked with grease and sealed on both sides with metal shrouds to prevent the ingress of dirtand moisture. The CV joint has six radial holes which provide for the attachment to the transferbox rear output flange. The joint is secured to the output flange with six bolts, which screw intothreaded holes in the flange. Three shims are fitted under each pair of bolts. The shims havetabs which are bent to secure the bolts. The CV joint is not a serviceable item and failure willrequire replacement of the rear propshaft assembly. The rear splined shaft mates with splines inthe rear shaft universal joint. A threaded hole is provided in the splined shaft to secure the frontand rear propeller shaft sections together. A machined surface on the shaft accepts the shaftbearing, which is a press fit.

Shaft Bearing AssemblyThe shaft bearing assembly consists of a pressed steel housing, a rubber bush and a ballbearing. The rubber bush is bonded into the housing. An internal metal ring, bonded to thebush, allows for the bearing to be press fitted into it. The rubber bush allows for small deviationsin alignment and also absorbs vibrational forces. The shaft bearing assembly is located onstuds, which are integral with the body, and secured with flanged nuts.

Rear Shaft AssemblyThe rear shaft assembly consists of a universal joint at the front and a CV joint at the rear. Therear shaft consists of a tube with the welded universal joint at one end and a welded splinedshaft at the opposite end.The universal joint is welded to the rear shaft tube. The opposite end of the universal joint has asplined bore which mates with the splined shaft on the rear of the front shaft assembly. A boltand washer is fitted through the splined bore and screws into the splined shaft on the front shaftassembly, securing the front and rear shaft assemblies together.The splined shaft accepts the CV joint which is secured with a circlip. The CV joint is packedwith grease and sealed on both sides with metal shrouds to prevent the ingress of dirt andmoisture. The CV joint has six radial holes into which, six knurled bolts are pressed. Theknurled shanks of the bolts provide a secure mounting for each bolt, preventing them fromrotating. Three shims are fitted under each pair of bolts. The shims have tabs which are bent tofurther secure the bolts. The CV joint is secured to the input shaft of the rear differential with sixflanged nuts. The CV joint is not a serviceable item and failure will require replacement of therear propshaft assembly.

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NOTES