BANAHAW TECHNOLOGICAL COLLEGE INC.

Lucban-Tayabas Road
Brgy. ManasaLucban,Quezon

INFORMATION SHEET 8.1-1

Name: ______________________________ Date: ______________

Section: _____________________________

I. TITLE: DIFFERENTIAL AND FRONT AXLE

II. OBJECTIVES: the students must be able to

1.Define terms associated with the differential and front axle system.
2.Match the names of the components in the differential and front axle system.
3.Identify the major parts of a differential system

What is a differential?
Differentials - A differential is a mechanical device which allows a flexible division of drive between
wheels to allow cornering.

How a differential works:

The drive from the engine rotates the large yellow crown wheel (1), which is attached to the smaller
blue cogs (2). These planetary gears can rotate freely, but work together to turn the green side
gears, which are connected to the half shafts (3). If one wheel needs to rotate faster than the other,
the green cogs permit this to happen.

TYPES OF DIFFERENTIALS

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 1 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
Limited-slip differential (LSD) - is a type of automotive differential gear arrangement that allows for
some difference in angular velocity of the output shafts, but imposes a mechanical bound on the
disparity.
In an automobile, such limited-slip differentials are sometimes used in place of a standard
differential, where they convey certain dynamic advantages, at the expense of greater complexity.

Torque sensitivity
This type includes helical gear limited-slip differentials and clutch, cone (an alternative type of clutch)
where the engagement force of the clutch is a function of the input torque applied to the differential
(as the engine applies more torque the clutches grip harder.

Speed sensitivity
Speed-sensitive differentials limit the torque difference between the outputs, based on the difference
in speed between the two output shafts. Thus for small output speed differences the differential’s
behavior may be very close to an open differential. As the speed difference increase the limiting
torque increases.

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 2 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
 INSPECTING SUSPENSION COMPONENTS

The inspection of the suspension components described in subsection “Suspension General (G)”
suspension arms and linkages, sub frames, etc., can be carried out in conjunction with this
subsection.

METHOD OF INSPECTION

SUSPENSION JOINTS AND WHEEL BEARINGS

Jack up the vehicles with suspension type, so that the wheels are clear of the ground.

Note:
Observe relative vertical movement between components during jacking up and lowering vehicle. It
may be necessary to carry out the following examinations by placing a suitable bar under each
wheel in turn and levering upwards. For suspension types check for excessive vertical movement
between stud axles and axle beams.

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 3 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
For suspension types, check for vertical movement between swivel and housing, and movement in
wishbone bearings.

Note:
It is important that type suspensions are jacked so that the suspension spring force is removed from
the ball joints, suspension arms must be clear of their stops. Failure to do this can result in defective
joints being missed.

For suspension types as it is not necessary to use the axle jack provided the wheel free lift can be
used to conduct the lower body inspection. Check for movement in suspension ball joints, tie bar
joints and MacPherson
Strut upper attachments by use of the play detector plates. With the wheels clear of the ground, spin
each wheel in turn and listen for any sound indicating roughness in the bearing. Also check for
tightness in the bearings.

Lower the road wheels onto Play detector plates, when initial contact is made with the plates (little or
no weight on plates) operate the Play detector plates. This is very important for suspension types.
After examination of suspension
Components, further lower the vehicle until most or all of the vehicle weight is on the play detector
plates, operate the plates again and examine all components.
Check: The amount of movement between the stub axle and the axle beam, or the movement in the
swivel joints, and the security of their attachment to the stub axle and suspension arms. For play in
upper and lower suspension ball
Joints and wishbone/track control arm bearings, for play at MacPherson strut sliding bushes and
glands, at MacPherson strut upper support bearings. This should also be checked when inspecting
steering components on lock to lock.

The movement of the wheel relative to the stub axle, and note the amount of play in the wheel
bearings.

Note:
Suspension ball joints can have free play lift as a feature of their design. Examine the condition of
the bonding between the metal and flexible material in the MacPherson strut upper support bearing.
If visible check the presence and effectiveness of the suspension retaining and locking devices.

Note:
It is not always possible to determine the ‘effectiveness’ of some types of locking device by normal
test methods,
Self-locking nuts. Only the presence of these devices is a test requirement check axle beam and
stub axles for cracks, damage and distortion.

8.1- 2 DRIVE SHAFTS AND COUPLING

Date Developed: Apr. 24, 2014 Document No.
Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 4 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
Inspect as follows while the wheels are jacked up.

1. With the vehicle in neutral gear, rotate the wheels when they are on each lock in turn, and
check visually the gaiters of the outer constant velocity joints while the pleats are expanded.

Check:

The wheel drive shafts for straightness and damage, Drive shaft couplings condition and security.

REASON FOR REJECTION

SUSPENSION JOINTS AND WHEEL BEARINGS

Excessive movement between a stub axle and an axle beam. Note:

Some vehicles (especially with ball thrust races) are designed to have a small amount of vertical
movement. Between a swivel joint and its housing.at a tie bar joint or wishbone bearing pin or bush,
at a MacPherson strut upper attachment.

Note:
Some MacPherson strut top bushes are designed to have lateral play when the suspension is
hanging free. Rejection is only justified when play is due to wear and/or maladjustment, etc.
Excessive roughness, or tightness in a wheel bearing. King pin loose in axle beam or its pin
retaining device missing, Excessive play in king pin and/or bush such that it is likely to adversely
affect the steering of the vehicle. Excessive play in a suspension ball joint, A ball joint securing nut
not tight or not locked, Excessive play in a pin or bush in an inner wishbone/track control arm
bearing pin or bush (cross check with subsection Excessive play in a MacPherson strut sliding bush
or gland,

Excessive movement in a MacPherson strut upper support bearing assembly, Roughness or

stiffness in a MacPherson strut upper support bearing (cross check with subsection ‘Steering
Systems’ C1e).Excessive play in a wheel bearing.
A serious deterioration of the bonding between metal and flexible material of an upper support
bearing of a MacPherson strut. A loose or insecurely locked unit in the upper support bearing
assembly of a MacPherson strut suspension retaining or locking device missing or ineffective.
Racked or distorted axle beam or stub axle.

DRIVE SHAFTS AND COUPLING

An outer constant velocity joint gaiter missing, split or insecurely mounted to its housing, A drive
shaft constant velocity joint excessively worn or insecure, A drive shaft coupling excessively worn or
insecure, A drive shaft flexible rubber or fabric coupling unit severely cracked or breaking up, A drive
shaft flexible rubber or fabric coupling softened by oil contamination, insecure or fouling any other
Date Developed: Apr. 24, 2014 Document No.
Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 5 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
part of the vehicle. A drive shaft bent or damaged, An insecure or fractured fastener securing a drive
shaft coupling bearing.
Checking drive shaft joints
Drive shafts require joints at either end to allow for angular change. Drive shafts turn at high speed.
The Universal and Constant Velocity Joints allow drive to be transmitted through an angular change.
This requires the shafts to be well balanced with minimal free movement. The objective of this
procedure is to show you how to check drive shaft joints for wear.
Part 1. Preparation and safety
Objective
 Check drive shaft joints for wear.

Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and
equipment that is appropriate for the task and which conforms to your local safety regulations and
policies. Among other items, this may include:
 Work clothing - such as coveralls and steel-capped footwear
 Eye protection - such as safety glasses and face masks
 Ear protection - such as earmuffs and earplugs
 Hand protection - such as rubber gloves and barrier cream
 Respiratory equipment - such as face masks and valved respirators
If you are not certain what is appropriate or required, ask your supervisor.

Safety check
 Never hold a shaft that is being driven by the engine.
 Make sure the vehicle is safely supported on a suitable vehicle hoist. The wheels need to be
free to turn.
 Make sure that you understand and observe all legislative and personal safety procedures
when carrying out the following tasks. If you are unsure of what these are, ask your
supervisor.
Points to note

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 6 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
  Drive shafts require joints at either end to allow for angular change. The most common type
of joint is referred to as a "Universal Joint", however the correct term for it is a "Hookes
Joint". They can also be known as a "Cross and Yoke Joint" or a "Cardan Joint".
 Drive shafts can contain components referred to as "Constant Velocity Joints". These are in
the form of a "Lobro Joint" or a "Double Cardan Joint".
 Drive shafts turn at high speed. The Universal and Constant Velocity Joints allow drive to be
transmitted through an angular change. This requires the shafts to be well balanced with
minimal free movement.
 A large amount of torque is transmitted through the shafts, so joint wear is normal.
 Constant Velocity Joints, mounted at the end of axles or half shafts, pass more torque than
Universal Joints mounted in drive shafts; they also operate at greater angles. Although they
are larger, they are still subject to wear. The indication of excessive wear is a clicking noise
when the vehicle is driven with the wheels at full lock. The noise is caused by the drive balls
being forced into, and out of the wear grooves. Severe cases are indicated by noise at lesser
steering angles.

 Drive shafts pass less torque than axles but they turn at much higher speeds. A small
amount of wear will cause an imbalance, which will lead to a vibration creating more wear.
 Any wear in a Hooke's Joint or a Constant Velocity Joint requires replacement of the entire
joint.
Part 2: Step-by-step instruction

1. Check driveshaft’s for looseness on any rear wheel drive vehicles, including pick-ups and SUVs,
inspect the drive shaft universal joints for signs of excess movement or rust. With the vehicle in a
condition where the drive wheels can be turned,
2. Rotate shaft & flange rotate the shaft and flange in opposite directions to check for wear. There
should be no movement in the joint. Any lateral movement, noise or signs of rust, should be
reported to your supervisor. Repeat this for each universal joint. On the 4WD vehicles, repeat
this procedure on the front drive shaft universals.
3. Raise the vehicle and turn wheels by hand with the vehicle driving wheels in a raised condition
where they can be rotated, turn the steering wheel to maximum lock, and rotate the road wheel.

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 7 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
 You should not hear any abnormal noises such as clicking or grinding. If you hear a distinct
clicking noise as the wheel rotates on full lock, it indicates that the balls and their housing inside
the joint are excessively worn. Turn the wheel to the opposite lock and repeat the procedure for
the other side.
4. Check sealing boots and clamps check the condition of the sealing boots. Make sure there are
no tears or splits, and that the retaining clamps are tight. A common practice to confirm that the
joint needs replacing without stripping the joint, is to drive the vehicle in a tight circle in a safe
place in one direction and then the other. If the noise increases and decreases in intensity in
relation to the rotational speed, the joint needs replacing, and you should report your findings to
your supervisor.
5. Diagnosing driveshaft u-joints

6. It is most common to find driveshaft u-joints on rear wheel drive automobiles. You may also find
them driving the front wheels on 4 Wheel drive models with I beam suspension like on older Ford
trucks and sport utility vehicles.
7. In some cases this flexible joint will have a grease fitting and will require regular service. In other
cases they are sealed from the factory and will require no lubrication at all. Drive-shaft u-joints
have been around for a long time. In fact I became familiar with these parts at a young age when
I got my learners permit and began driving.

8. Common universal joint problems: One of the most common signs of a damaged or bad
universal joint is when a clunk is heard when the transmission is shifted into gear or moved from
reverse to drive. This clunk can be caused by other problems but may be a sign of excessive
clearance in the u-joints.
9. When a driveshaft flexible joint is on its way out it can also cause vibrations at higher speeds.
This may feel like a wheel balance problem. A way to tell the two problems apart is in most
cases a worn u-joint will cause vibration during acceleration or deceleration. A tire balance
problem will create a steady vibration regardless of throttle position.

ANALYZE KING PIN CONDITION ACCURATELY

Kingpin & bushing replacement

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 8 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
Remove old bushings. Use the sockets in a vise as a "press" and crank 'them out. (Or use a
hammer and driver).

Install new bushings. Line up the hole in the bushing with the hole and tap in the bushing.

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 9 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
Reaming bushings. Now that the bushings are in, they need reamed to size, as they have "crushed"
when pressed in.

Install. Put spindle on axle, with the bearing on the bottom, face the bearing so that the groove is
facing down (It won't fill up with water/dirt). Take the kingpin and install the cupped washer and felt.
Lightly grease the pin.....then slide it into the spindle, keeping the notch lined up with the hole in the
axle. Install the retainer pin and new grease zeros and yet done.

SELF CHECK

I. Choose the best answer. Write your answer on the space provided before the number.

______ 1. This is the mechanical drive that enables flexible division of drive between wheels to allow
cornering.
a. steering b. differential c. suspension

______ 2.What is the indication of excessive wear in the Constant Velocity Joint?

a. when the accelerator has low depressing.

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 10 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
 b. when there are vibrations in the steering of the vehicle.
c. a clicking noise when the vehicle is driven with the wheels at full lock.

______ 3.. _______________ is a type of automotive differential gear arrangement that allows for
some difference in angular velocity of the output shafts.

a. Limited-slip b. torque c. speed

______ 4. When are MacPherson strut top bushes designed to have lateral play?

a. If the wheel bearings have approximate allowances

b. If the axles are tightened
c. If the suspension is hanging free

______ 5. How often must an infrequent drive change the brake pads.

a. every 8-12 months

b. every 6-12 months
c. every 3 months

______ 6. Which of the following does not refer to the universal joint?

a.Hookes joint b. Cross and Yoke joint c. Lobro joint

______ 7. What do you call the kind of brake when shoes press on the outside of the drum?

a. clasp brake b. hydraulic brake c. disc brake

II. For nos. 8-10, refer to the illustration. Identify the problem in the differential system

8. _______________________________
9. _______________________________
10. ______________________________

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 11 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
 Answers
I. Multiple Choice
1. b. differential
2. c. a clicking noise when the vehicle is driven with the wheels at full lock.
3. a. Limited-slip
4. c. If the suspension is hanging free
5. a loose shift knob
6. a. every 8-12 months
7. c. Lobro joint
II. Identification
8. leaking filler drain plug
9. worn carrier bearings
10. bent or damaged axle housing
Date Developed: Apr. 24, 2014 Document No.
Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 12 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
 BANAHAW TECHNOLOGICAL COLLEGE INC.
Lucban-Tayabas Road
Brgy. ManasaLucban,Quezon

WORK SHEET

Name: ______________________________ Date: ______________

Section: _____________________________

I. TITLE: DISASSEMBLING DIFFERENTIAL SYSTEM

Date Developed: Apr. 24, 2014 Document No.
Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 13 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
II. OBJECTIVES: the students must be able to

 Disassemble differential system properly

 Demonstrate occupational health and safety in doing the activity

III. TIME:60 min.

IV. TOOLS and MATERIALS

a. Differential system f. Safety glasses

b. Pry bar g. Set of box wrench
c. Axle lubricant h. Set of combination wrench
d. Shop towel i. Set of socket wrench
e. DOT 3 Brake fluid j. Vise grip

V. Procedure

Differential Disassembly Procedure

CAUTION: Do not attempt to remove the end cap of the differential. All servicing will be done
through the large window of the differential case.

1. Remove differential from axle housing (refer to vehicle service manual).

2. Remove and discard ring gear screws.
3. Using a non-metallic hammer or brass drift punch, drive the ring gear loose from the differential
case pilot and remove. Cross-Pin Lock Screw Differential Cross-Pin
4. With the differential cross-pin removed, position a small pry bar between the outboard spring and
the differential case on each side of the installation window. Slowly pry the spring pack out of
the differential with the two (2) pry bars. Once the spring pack is approximately half way out,
wrap a rag around the spring pack and remove the rest of the way by hand.
5. Inspect the spring retaining plates for cracks and replace if necessary.
6. Remove the differential pinion gears through the installation window by aligning the half-rounds
of the cone clutch with the half-round of the installation window and rolling the pinion gears to
the window.
7. Once the pinion gears have been removed, remove the side gear and cone assemblies.

CAUTION: DO NOT MIX GEAR/CONE ASSEMBLIES. Mark each assembly “L” or “R” so that they
will be reassembled in their original position.

8. Degrease the differential case and cone assemblies.

9. Inspect the clutch surfaces for galling. If the cone and cone seat (case) are galled, there is no
point completing the rebuild. The differential is beyond repair and should not be used.

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 14 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
10. If no galling is present, lightly scuff the clutch surfaces with 250-300 grit emery cloth. This will
remove any glazing that may have occurred and restore torque biasing capabilities. Thoroughly
clean the cone and cone seat to remove any debris.

Differential Assembly Procedure

1. Apply liberal coating of axle lubricant to the cones and cone seats and install them in their original
position.
2. Align the half-rounds of the cones with the half-rounds of the case. Install the pinion gears(with
the thrust washers in place) and rotate them into position. Check pinion alignment byinserting the
cross-pin through each pinion bore.
3. Install the spring pack as a compressed unit. This can be done by using two (2) steel plates, a “C”
clamp, and a striking block.
4. Place the differential cross-pin in the case only far enough to go into one (1) pinion gear.This will
keep the pinion bores aligned with the case bore during spring pack installation.
5. Position the compressed spring pack fixture against the two (2) side gears through the installation
window. Carefully drive the spring pack out of the fixture into the differential by striking the striking
block.

NOTE: Do not strike the spring block directly as this may damage the spring retaining plates.

6. Drive the spring pack into the differential until the spring retaining plate holes are aligned with the
case and pinion bores. Install cross-pin to ensure alignment.
7. Reinstall differential (refer to vehicle service manual).
8. Torque differential cross-pin lock screw to 25 lb-ft.
9. Install axle housing cover.
10. Fill axle level with filler hole with the recommended axle lubricant for use with limited-slip
differentials.

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 15 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
 Problems of Differential System

RUBRIC FOR PERFORMANCE

Dimension Highly Competent Competent Fairly Not Yet

Competent Competent
4 3 1
2
1. Proficiency Perform the task with Perform the task Perform the task The task is not
of performing exceptional with with competence performed.
disassemblin performance competence and but below
g of with standard standard
differential performance. performance.
system

2. Level of Student was able to Student was Student was able Student was
needed complete the task able to complete to complete the unable to
assistance without assistance the task with task with complete the
little assistance moderate task without
assistance from major
instructor and assistance
peer
3. Safety/ Student followed all Student followed Student Students
Work habits safety rules and have most safety attempted to failed to follow
PPE all the time of rules, may have follow safety significant
training. forgotten one rules but failed to safety rules
PPE. meet several and PPE.
PPE.
4. Speed/ Work finished ahead of Work finished No concept of
Time time close to time
deadline
5. Clean up Cleaned his assigned Students made Student Student did
and return area and returned effort to clean somewhat not clean
tools tools to their proper assigned area cleaned assigned area
place. and returned assigned area or return tools
tools top and did not to proper

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 16 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01
 proper place. return tools to place.
proper place.

POINTS EARNED NUMERICAL DESCRIPTIVE

Highly Competent
16 - 20 91-100

Competent
11 - 15 86-90

Fairly Competent
6 - 10 81-85

Not Yet Competent

1-5 76-80

Grade: ______________________________

Teacher’s Comment:
________________________________________________________________________________
________________________________________________________________________________
______________________________________________________________________.

Date Developed: Apr. 24, 2014 Document No.

Issued by:
SERVICING DIFFERENTIAL Date Revised: Dec. 20, 2018 Page 17 of 17
AND FRONT AXLE Developed by:
Mr. Ryan M. Fabricante
Revision # 01