Barn of Parts Cross Shaft Saver/ RR upgrade

[hibshman25]

The std cross shaft which measures 5/8" in diameter has been a bit of week point and prone to shearing off completely. Some of the LE models came through with Cat's RR version which is a larger diameter aluminum shaft. Using this shaft requires new flange caps and other bolts as well. The RR upgrade is a great option, and at first I didn't really think it was worth competing with but after some figuring I think I have come up with an option worth building.

My potential idea is to utilize the stock 5/8" cross shaft and replace the two flanged steel collars with one continuous steel sleeve that boasts the same diameter as the RR shaft. To obtain correct spacing and a flange two washers are utilized on each end.

List price on all the RR parts to upgrade is around $95 with the collars costing around $25 each. I'm thinking I could offer my kit for around $45.

 

[actionjack]

I’d buy.

Interesting some LEs shipped with larger part?

 

[hibshman25]

I’d buy.

Interesting some LEs shipped with larger part?

Maybe I should correct myself, I know some of the LE vipers in 15 and I believe 16 had the RR shaft. Don't know for sure in 17 if the LE's still had the upgrade.

 

[ROCKERDAN]

That seems like it would do the trick Travis....

There was talk of the bolts being too short, and where they would shear off....Do you feel like longer bolts would be smart? Im not even sure if a longer bolt would work or not?

Dan

 

[hibshman25]

That seems like it would do the trick Travis....

There was talk of the bolts being too short, and where they would shear off....Do you feel like longer bolts would be smart? Im not even sure if a longer bolt would work or not?

Dan

I think the issue with the bolts was that they did not extend beyond the collar. The shear point on those that broke was right where the collar stopped. A bolt extending beyond the collar would add extra strength.

Beings I am using a continuous steel sleeve there is no defined edge/shoulder point for failure. Obviously longer bolts are not going to hurt. To do this, one would have to run a tap farther into the shaft as there are not enough threads in the stock shaft. The sleeve alone is going to add substantial strength over the stock shaft, so I'm not really sure longer bolts are worth the effort.

 

[Soldier'spapa]

My 18 LE did not come with the RR parts. I recently replaced the stock shaft with the RR parts.

 

[ROCKERDAN]

Gotcha, that makes perfect sense Travis.

Do you feel that the tunnel will need beefing up too? I think the RR has more beefy bracing on side tunnel.

Or will this be OK with stock tunnel?

thanks,
Dan

 

[Turtle]

Gotcha, that makes perfect sense Travis.

Do you feel that the tunnel will need beefing up too? I think the RR has more beefy bracing on side tunnel.

Or will this be OK with stock tunnel?

thanks,
Dan

The stock tunnel is the next weak link. In fact, my tunnel started showing signs of cracking and I never broke the upper cross shaft. Mine is a 2015 SE model with the weaker shafts. I upgraded everything (upper cross shaft and lower shock mount) to the RR parts, then reinforced the tunnel.

 

[Byam]

That seems like it would do the trick Travis....

There was talk of the bolts being too short, and where they would shear off....Do you feel like longer bolts would be smart? Im not even sure if a longer bolt would work or not?

Dan

I have the "rr" bolt on my sled. Just a little bit longer

 

[hibshman25]

Gotcha, that makes perfect sense Travis.

Do you feel that the tunnel will need beefing up too? I think the RR has more beefy bracing on side tunnel.

Or will this be OK with stock tunnel?

thanks,
Dan

I am working on tunnel reinforcement plates too. Link below has pics. Since some tunnels are cracking without even having a cross shaft break the reinforcement plates will just be extra insurance.

 

[ROCKERDAN]

Yeah I saw the plates, good idea.

On these cross shafts, I assume the suspension still fits onto the shaft even with larger diameter correct? Is there that much play in there now, that it still fits onto shaft? I guess i need to look closer at mine.

Dan

 

[hibshman25]

Yeah I saw the plates, good idea.

On these cross shafts, I assume the suspension still fits onto the shaft even with larger diameter correct? Is there that much play in there now, that it still fits onto shaft? I guess i need to look closer at mine.

Dan

The sleeve OD matches the OD of the collars you are removing.

It's quite an odd design to have steel collars riding on the steel pivot arm pocket. It doesn't really seem to be a wear item though as I can't really find any complaints on the forum about having a wear issue. At 3k miles on my winder I really see no wear issues to be concerned about either.

 

[Chris Rose]

Yeah I saw the plates, good idea.

On these cross shafts, I assume the suspension still fits onto the shaft even with larger diameter correct? Is there that much play in there now, that it still fits onto shaft? I guess i need to look closer at mine.

Dan

The bushings are the same diameter for both size shafts, that's where the rails contact. The cross shaft is thicker between the two bushings and thins going into the bushings.

 

[hibshman25]

Here's a photo to clarify the setup.

 

[ROCKERDAN]

Ok I see, great pics.....I was just looking at fiche and makes more sense. So the suspension ears go over the outer bushing, not the shaft itself.

I think your design will do well then....I think you should combo this kit with the coolant hose fix! Everyone should get these and do it all in same install.

Fiche pic....