DIFFERENTIAL

Ex.No: Page No:

DISMANTLING & ASSEMBLING OF DIFFERENTIAL UNIT

AIM:
To study, dismantle, inspect and assemble the given Differential unit.

TOOLS REQUIRED:
1. Hammer 2. Socket 3. Extension rod 4.Racket 5. Leverage rod
6. Strain divider

FUNCTION:
A vehicle's wheels rotate at different speeds, mainly when turning corners. The differential
is designed to drive a pair of wheels while allowing them to rotate at different speeds. In vehicles
without a differential, such as karts, both driving wheels are forced to rotate at the same speed,
usually on a common axle driven by a simple chain-drive mechanism. When cornering, the inner
wheel needs to travel a shorter distance than the outer wheel, so with no differential, the result is
the inner wheel spinning and/or the outer wheel dragging, and this results in difficult and
unpredictable handling, damage to tires and roads, and strain on (or possible failure of) the entire
drive train. In automobiles and other wheeled vehicles, a differential is the usual way to allow the
driving road wheels to rotate at different speeds. This is necessary when the vehicle turns, making
the wheel that is travelling around the outside of the turning curve roll farther and faster than the
other. The engine is connected to the shaft rotating at an angular velocity. The driving wheels are
connected to the other two shafts, and they are equal. If the engine is running at a constant speed,
the rotational speed of each driving wheel can vary, but the sum (or average) of the two wheels'
speeds cannot change. An increase in the speed of one wheel must be balanced by an equal
decrease in the speed of the other. (If one wheel is rotating backward, which is possible in very
tight turns, its speed should be counted as negative.)

DIFFERENTIAL:
A differential is a device, usually, but not necessarily, employing gears, which is connected to the
outside world by three shafts, chains, or similar, through which it transmits torque and rotation.
The gears or other components make the three shafts rotate. It may seem illogical that the speed of
one input shaft can determine the speeds of two output shafts, which are allowed to vary.
Logically, the number of inputs should be at least as great as the number of outputs. However, the
system has another constraint. Under normal conditions (i.e only small tyre slip), the ratio of the
speeds of the two driving wheels equals the ratio of the radii of the paths around which the two
wheels are rolling, which is determined by the track-width of the vehicle (the distance between the
driving wheels) and the radius of the turn. Thus the system does not have one input and two
independent outputs.It has two inputs and two outputs.
PRINCIPLE
1. Input torque is applied to the ring gear, which turns the entire carrier. The carrier is connected
to both sun gears only through the planet gear. Torque is transmitted to the sun gears through the
planet gear. The planet gear revolves around the axis of the carrier, driving the sun gears. If the
resistance at both wheels is equal, the planet gear revolves without spinning about its own axis,
and both wheels turn at the same rate. If the left sun gear encounters resistance, the planet gear
spins as well as revolving, allowing the left sun gear to slow down, with an equal speeding up of
the right sun gear.
The differential has three jobs:
1. To aim the engine power at the wheels.
2. To act as the final gear reduction in the vehicle, slowing the rotational speed of the transmission
one final time before it hits the wheels.
3. To transmit the power to the wheels while allowing them to rotate at different speeds (This is
the one that earned the differential its name.)

DISMANTLING:
Given- Differential unit.
1. Remove Output shaft/drive flange
5 Pulling off Tapered roller bearing inner race
6 Remove Tapered roller bearing outer race
7 Remove Bearing body for tapered roller bearing
8 Remove Differential
9 Remove O-rings
10 Remove Adjusting ring for tapered roller bearing
11 Remove Output shaft/drive flange
12 Remove Tapered roller bearing outer race
13 Pulling off Tapered roller bearing inner race
14 Drive out Speedometer drive gear with drift Fit together with driver bushing
15 Remove small bevel gears, large bevel gears.
16 Circlip - Do not remove the circlip until after removing the drive flange as the compression
spring is pre-tensioned.

INSPECTION:
1. Visually check the final drive gear. It is riveted onto differential housing and then machined.
If differential or final drive gear is damaged, replace differential housing along with riveted final
drive gear.
2. Visually check all the spare parts and replace required parts. Replace O rings always.
ASSEMBLING:
1. Place, position, install, press and assemble all the spare parts as needed in the reverse order of
dismantling.

RESULT:
Thus the given Differential Unit is dismantled, inspected and assembled.