Dongfeng GX Transmission shaft with sliding fork assembly 2201010-HA401

The assembly features a one-piece integrated structure that combines the transmission shaft body with a precision-machined sliding fork—optimizing power transfer efficiency while accommodating driveline movement. The sliding fork is directly welded to the shaft’s intermediate section (using robotic MIG welding for uniform strength) and features internal splines that mate with the sliding yoke, allowing axial movement (to compensate for suspension articulation or chassis flex during driving). This design eliminates the need for separate fork-to-shaft connections, reducing potential failure points and ensuring consistent torque transmission. Additionally, the shaft is balanced to ISO 1940 G6.3 standards (maximum residual unbalance ≤ 5 g·mm/kg) to minimize vibration at high speeds (up to 3000 RPM), preventing premature wear of driveline components

Shaft Body: Constructed from seamless cold-drawn alloy steel (45# or 40Cr) with a wall thickness of 5-8mm—selected for its high tensile strength (≥ 650 MPa) and fatigue resistance. The material undergoes quenching and tempering heat treatment, enhancing its surface hardness (HB 220-250) to withstand torsional stress and impact loads (e.g., during sudden acceleration or rough-road driving).

Sliding Fork: Fabricated from forged alloy steel (20CrMnTi) for superior toughness and wear resistance. The fork’s internal splines are precision-ground to a Ra ≤ 0.8μm finish, reducing friction with the sliding yoke and ensuring smooth axial movement over the assembly’s service life.

Universal Joints (U-Joints): Equipped with high-carbon chromium bearing steel (GCr15) cross shafts and needle bearings, capable of withstanding high rotational speeds and angular misalignment (up to 3°) between the transmission and axle. The U-joints are sealed with nitrile rubber (NBR) boots to prevent contamination by dust, water, and grease leakage

As a core component of the Dongfeng GX’s driveline, this assembly fulfills three essential functions:

Torque Transmission: It transfers rotational power from the transmission (or transfer case, for 4×4 GX variants) to the rear axle, ensuring efficient power delivery to the drive wheels—critical for heavy-load transport (up to 10 tons) and uphill climbing.

Driveline Flexibility: The sliding fork’s axial movement compensates for changes in driveline length caused by suspension compression/extension (e.g., over potholes) or chassis twist, preventing binding or damage to the transmission or axle.

Vibration Damping: The balanced shaft design and high-quality U-joints minimize driveline vibration, reducing noise transmitted to the vehicle interior and protecting sensitive components (e.g., transmission gears, axle bearings) from premature wear

This transmission shaft assembly meets global commercial vehicle standards, including China’s GB/T 12459 (Steel pipe flanges) and ISO 6892 (Metallic materials—Tensile testing), as well as IATF 16949 quality management requirements. Each unit undergoes comprehensive pre-shipment testing:

Torque Load Testing: Subjecting the assembly to 1.5× the maximum rated torque (2700 N·m for heavy-duty variants) for 10 minutes to ensure no shaft deformation or joint failure.

Balance Testing: Using a dynamic balancing machine to verify residual unbalance meets ISO 1940 G6.3 standards, reducing high-speed vibration.

Durability Testing: Simulating 500,000+ rotational cycles (equivalent to 300,000+ km of driving) under variable torque loads to confirm fatigue resistance.

Environmental Testing: Exposing components to salt spray (800 hours), high temperature (120°C for 200 hours), and low temperature (-40°C for 200 hours) to validate corrosion resistance and performance stability.

Backed by a 24-month manufacturer’s warranty, the assembly ensures reliable driveline operation for Dongfeng GX’s heavy-duty applications (e.g., long-haul freight, construction site transport)