Drive Shaft Installation Hassles

[nothingbutadeere]

Happy Snow Day from Minneapolis,

I am converting my round drive shaft to a hex shaft in my '78 Liquifire and having a devil of a time trying to wrestle it in. On the chain case side I put the inside flange, bearing, O ring and outside flange on the shaft and can insert into the respective chain case hole. However, when I go to put the other end into the clutch side there isn't enough clearance to get it in the hole. When I took out the original drive shaft it literally fell out. All the measurements on the hex shaft match up with the original round shaft, but can't for the life of me figure out why I am not able to simply install the drive shaft. Just a note, I do have the original shop manual for this sled and have followed it to a T. Any guidance from you professionals here would be greatly appreciated. Too much snow out there to not enjoy the old gal.

Todd

[Hec In Omaha]

nothingbutdeere,

Did you try moving the drive wheels towards the center of the shaft? This may give you enough wiggle room to slip it in the clutch side. At least that's how I did my Trailfire. Good luck.

Hec

[nothingbutadeere]

Thanks Hec for the suggestion, the drive wheels are pressed on so not able to move them and the doesn't seem to be what's holding it up. It is getting caught up when the outer flange meets up with the inside tunnel. I have the bearing butted up against the shaft where it starts the hex with the lip of the bearing facing the gear. The opposite side of the drive shaft gets hung up on the tunnel. Perplexed at this point.

[Hec In Omaha]

Is the overall length of the drive shaft the same? Is the length of the rounded ends of the shaft the same as the original? This is the measurement from the end of the shaft to where the shaft changes diameter If that dimension is less than the original dimension I could see that the new center to center distance of the bearings would have been increased and therefore cause and issue. Just thinking out loud.

Hec

[nothingbutadeere]

Hec keep thinking out loud, that's kinda what I am looking for. The measurement on the ends are identical between the hex and the rounded shaft and the drive wheels are spaced according to the original shaft as well.

[harleysportster]

double check that you have the bearings oriented in the correct position. The wider part of the bearing where a locking collar would normally go has to face the spline end of the shaft.
When you get it in, it should look like this.

[nothingbutadeere]

Thanks Harleysportster I do have both bearings with the wide part facing the spline end of the shaft. I'll get back out there and give it another shot.