1996 challenger drive shaft?

[DonoBBD]

He guys I thought I would throw this out there.

I picked up this little boat for the kids so we could have a second boat at the camp. Now it picked up a small stone and spun the splines off the drive shaft on the motor end. The PTO splines on the motor are fine just the drive shaft end is dinked.

So I looked around on the net till I found a drive shaft that was the same. I did get it here and I seen that there was some differences. First there was only one grove and not two on it then the one grove that is there is not in the same place as any of the two on the stocker.

Now I look up the info on the drive shaft for the boat. IT turns out that this boat is to have a 46.5cm drive shaft and the one that was in the boat was 45.8cm a total of 7mm to short.

Question number one. Would this drive shaft being 7mm to short or 1/4 inch to short have buggered the splines?

Question number two. If no to question one can I have a grove cut into the right spot on this one and use it?

Question number three if yes to question one....... where the heck can I find the correct drive shaft?

Thanks Again Don.

 

[DonoBBD]

Nothing guys?

 

[Murph_13]

DonoBBD,

The right, or original driveshaft, for the 96 Challenger is no longer available. It was superceded by the driveshaft used in the 97 Challenger which does have differences in the number of or location of the grooves (the grooves that you set your tension on the rubber boot and carbon ring to seal the driveshaft). I can't remember specifically the differences as it's been a long time since I replaced the PTO and driveshaft on my 96 Challenger, but I do remember that the original design driveshaft was not available any longer and was superceded by the 97 design which did have some minor differences in the machined area where the carbon ring rides.

I would definitely look at replacing both the driveshaft and the PTO. If the splines spun on the driveshaft I'm sure that there has got to be some wear/damage to the splines on the PTO. After having my PTO and driveshaft that had spun (spline damage) out of the boat and in hand, I could play with the driveshaft depth into the PTO and find areas where it would grab and seem fine and I would have to get it in just the right spot to spin the driveshaft in the stationary PTO, otherwise they would seem fine. So again, I would definitely look at replacing both while you've got it apart. Getting the PTO off is not that difficult as long as you have the spline tool for the impeller/PTO.

I ended up buying the driveshaft and PTO off eBay. The drivehaft was a new aftermarket (around $180) and the PTO was a used (around $50-60), but in like new condition off of a much newer ski. The PTO for the 96 Challenger is also common to a number of other boats/skis and I believe all the way up to a 2005 application which I believe mine was from.

Good luck with it.

 

[Murph_13]

DonoBBD,

The 96 Challenger driveshaft is P/N 272 000 072

The 97 Challenger driveshaft is P/N 204 120 045

You'll have to search for the 97 P/N to find the driveshaft you need.

The PTO P/N for both is 290 958 056. I'll try to find the applications that use this PTO if you're thinking about replacing both. I couldn't answer your questions about using a driveshaft that's 7mm too short and having a groove machined into it. I personally wouldn't go that route.

 

[DonoBBD]

The PTO is brand new before this happened this is why I think that the shaft being 7mm to short is 90% of the problem.

See picture added of the PTO.

Any chance you know the length of the 204-120-232 drive shaft? I can have a grove cut into it if I need I am good with that but not sure if the length is the problem?

Don.

 

[Murph_13]

Don,

Sorry, I don't have the dimensions for the driveshaft (204 120 232). The splines on your PTO do look good.

I agree that the shorter driveshaft may be a big part of what caused the failure. The splined area of the driveshaft is convex and combining that with the shorter length most likely produced less surface contact between the PTO and driveshaft splines resulting in the failure.

 

[Murph_13]

Don,

Here's an eBay listing for a new aftermarket (made in China I'm sure! But hey, a new Sea Doo/Bombardier impeller will come with a made in Taiwan sticker on it!):

http://cgi.ebay.com/ebaymotors/SEA-...Personal_Watercraft_Parts&hash=item2ea5552f37

It's a "Buy It Now" for $139.99 plus shipping ($18.80 for me, not sure for you...not sure of the difference shipping to Cananda...it's out of Illinois).

Todd

 

[DonoBBD]

Thanks so much for the link. I will ask about the length and if it is different than the one I have then I will get it. Two shots of the wiped end.

Cheers Don.

 

[Murph_13]

It looks like it had spline contact nearer to the end of the splined area instead of the middle where the splines have the largest diameter. Again, I think you're right about the shorter length playing a big part in the failure.

Hope you get it back on the water soon! Boating season is too short for us up here in the north!

Cheers...

Todd