Forum DANGEL

I removed the transfercase from the vehicle yesterday and wanted to post some pics of the "unique" setup that was connecting the transmission to the transfercase:


here you can see the order in wich it was installed - transmission would be on the right side:



here the drilled splines of the transfercase wich i might be able to save




here the backside of the transmission still in the car:




my guess is, that at some point the double cardan broke, and someone just slapped on a single cardan, ball and casing wich of course was to short, so he extended it, pinned and welded it to the transfercase inputshaft.

as far as i understand it i have to ditch the ball, the ballcasing and the single cardan (a second cardan came as a spare with the car) and replace it all with the double cardan unit.

do you see any other parts i´m missing, and should order with the double cardan? anything additional to check for while i´m in there? if you need additionl pictures to confirm my suggestion please let me know

thanks for the help

Ok, i will try to make a simple answer
At first, i confirm that you have the transfer box wich working with the double cardan.

And then, here are the right mounting of your transmission:


The double cardan (with the big ring between the two cardans) and the snubber below.
You only must find a double cardan and the part in red.

The snubber role is just limiting an excessive movement between the two gear box but it is very important because without it, the double cardan breaks fastely.

If you will not find snubber (and only in this case) you can contact me with a private message because i have already made it.

Finally you must secure the gear box with shorter BTR screws.

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La mécanique c'est vraiment chiant... mais qu'est ce que j'aime bien ça!!

Thanks Hellaz - that helps a lot!

i contacted this guy: https://www.leboncoin.fr/equipement_auto/1618343811.htm

and this company: https://www.leboncoin.fr/equipement_auto/735709371.htm ( i´m not shure if he is still active, couldn´t get a response yet)

concerning the missing parts.

if i have no luck sourcing them i gladly contact you about the "snubber" - and as i have 1 good rear cardan with the needed splines i might be able to get a doublecardan made by this guys localy:


http://www.plasounig.at/plasounig-techn ... 2&Itemid=3

maybe we can even get a batch of them made, if that could help other dangel owners.

i´ll keep you updated and realy appreciate your help.

thanks

hellhaz, to bother you one last time with this mess:

could you provide me with the the total length of the double cardan unit, for the case i´m forced to have it fabricated.
the selfmade snubber looks great btw. - i might be able to copy that myself if you can provide the dimensions of it, and maybe spill the beans on how you made the insert inside the tube part.

thanks again for all the help

I don't know the total length of the double cardan.
I will try to mesure it but i don't know when because i'm busy for this time.
The same thing for the snubber mesures.
I will try to take the mesures as soon as possible.

If you can do making a double cardan, try to made it with grease nipple and a damping device if possible.
We are a few to be intersted by double cardan...

see you soon

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La mécanique c'est vraiment chiant... mais qu'est ce que j'aime bien ça!!

Hi Lowrider,

The circular plate you find in the car is probably the plate from the double cardan (as shown on the pic)
You should contact cardan.com - Flament French company - I found the half cardan I guess but you have to check the good dimension with them
On the pic I give you the part number 023-861-0 witch is the spare part of the double cardan and front axle
The other pic is the half cardan from cardan.com

Best regards

Philippe

thanks a lot Philippe - i made my cardan crashcourse yesterday and it seems we sport din 1100 cardanjoints with the 23,8x61,2 bearings - sadly about the weakest option out there.

since i have a working cardan with both slipjoints, the middle ring and a second cardan with good bearings i´m only missing the 2 flange yokes (learned that term yesterday) wich are bolted with the middle ring, to end up with a working double cardan.


and this is what i found: https://www.dennysdriveshaft.com/p2533_ ... h_2.2.html

the hight from the flange to the center of the bearing is about 28mm - i just need to confirm thats in the range of the stock parts, so the overall length wont change

also found a china option with round flange, 4 or 6 bolt pattern, and hight of 40mm for 12 euro....but lets not cheap out;-)







i´m almost willing to play the testmule and use the spicer part to fab up the double cardan, since it would deliver a budget friendly option to repair the double cardan, or make a new one from scratch for little money by getting the normal u joint - i fount them used for about 40.--
2 spicer flanges for about 40.-- a piece - so 80.-- for both
1 extra bearing cross wich i found for around 15.-- - also with grease nipple

just get a middle ring made and you have a complete double cardan for under 150.--...and not the 650.-- dangel tries to charge for it.

any thoughts on this? am i missing something?

edit: this looks like the flange yoke used by cardan.fr on the half-double-cardan: https://www.cardyfren.com/en/sae-flange ... 88-mm.html

Hi Lowrider

It's fine if you have a cheaper way to restore the double cardan

Don't forget to add the compression spring in the transfert case axle - I don't know strengh and dimensions
and the 56 mm setting as show on the pic

Good luck

Philippe

Thanks for the reminder Philippe - had thought about that spring already. it presses against the inside of the smaller slipjoint i guess? my small diameter slipjoint on the other hand is drilled and splined all the way through and has nothing the spring could press against....i will weld a collar in for it to press against.


i´m still in search for the overall length of the complete double cardan in order to get the recomended 56mm correctly adjusted.
what i seem missing ist the outer ring around the tranfercase input shaft, visible in both the drawings and Hellhaz pictures - it has the partsnumber 230321 in the dangel parts catalouge....mine looks like that:

Hi lowrider

The ring(#2 on the drawing) is a protection shaft only - it's an alumiun part bonded in the case with Loctite I remenber - you can carry out a new one with a lathe

It's sems that your gear speed axle ( low/high sped selector ) is broken (staying half M8 )

Philippe

Oui Philippe, bien vu!!!
mais comme ce n'était pas vraiment le sujet, je n'ai pas pensé à le préciser, cette photo était pour montrer le double cardan et c'était bien pratique de ne pas avoir la commande devant pour voir mieux!
En tous cas, ton intervention est bienvenue, pas facile d'expliquer tout ça en anglais!!

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La mécanique c'est vraiment chiant... mais qu'est ce que j'aime bien ça!!

Thanks Philippe and Hellhaz - i really appreciate your efforts. you can always answer in french and i run the answer through the translater .

I can fabricate the ring myself, no problem - just would need the inner diameter of it - the yoke isn´t actually riding on the ring, or is it?

i dropped my one working single u-joint of at a local cardan specialist to get an price estimate for the 2 missing flange yokes and new cross-bearings, if possible with grease-nipples. one of them with the hole in the middle to get the bolt in that holds the yoke to the transmission. what i still need is either the overall length of the double cardan or even better the hight of the flange yokes in the middle, so he knows wich ones to order

messurement E in this picture, on the both middle flange yokes bolted to the ring of the doublecardan, is what i´m looking for:



as for the "snubber" (the red part in Hellhaz picture) i already found a neat solution for the sliding part of it:



a 26 mm multitooth-socket fits like a glove over the stump - but i would need the distance between the snubber and the transmission in resting position to know for how much travel it must allow, and wich part of it exactly makes contact with the transmission to limit the travel - the sliting ring or the frame?

so much for the machanical - today i´m going to look a bit into the bodywork, the few rustpots and the outer runners of the front subframe wich are completely desintegrating.

thanks for all the help

joerg

Hi lowrider,

I have only one picture to help you regarding the dimension of the double cardan. Measure your central part and compare with the pic to find approximativement the scale. After measure the flange yoke of the pic and calcutate E

The rubber must be completly in the 26mm socket

Bye
Philippe

thanks Philippe - thats perfect, now i can calculate the overall length of the double cardan

concerning the snubber:
so the round part of the snubber actually makes contact with the transmission in resting position? it only allows for distance-increase between transmission and tranfercase, but not for distance-decrease?
is that correct?

Hi Lowrider

About the snubber, i don't inderstand the meaning of the question - maybe could you make a manual drawing to describe ?

Thanks

Philippe