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CH39 Drive Axles and Differentials

The document discusses drive axles and differentials. It describes the components and functions of front-wheel drive axles including CV joints. It also discusses rear-wheel drive shafts and U-joints. The document explains the purpose and operation of differential assemblies, including limited-slip differentials. It covers the types of axle shafts, bearings, and gears used in differentials. The document provides tips on diagnosing issues, assembly, maintenance, and common noises related to drive axles and differentials.

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Suzan Khoury
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76 views40 pages

CH39 Drive Axles and Differentials

The document discusses drive axles and differentials. It describes the components and functions of front-wheel drive axles including CV joints. It also discusses rear-wheel drive shafts and U-joints. The document explains the purpose and operation of differential assemblies, including limited-slip differentials. It covers the types of axle shafts, bearings, and gears used in differentials. The document provides tips on diagnosing issues, assembly, maintenance, and common noises related to drive axles and differentials.

Uploaded by

Suzan Khoury
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Chapter 39

Drive Axles and Differentials


Front-Wheel-Drive Axles
• Also called axle shafts.
• The constant velocity (CV) joints transfer
uniform torque at a constant speed over a wide
range of angles.
CV Joint Functions

• Fixed Joint
– Does not move in and out to change shaft
length.
– Is used as the outboard joint.
• Plunging Joint
– Allows for a change in axle shaft length to
allow movement of the suspension.
– Is used as the inboard joint.
FWD Applications
• Shafts can be solid or tubular, equal or
unequal length, with our without damper
weights.
• Equal length shafts are used to reduce
torque steer.
• A damper is used to reduce harmonic
vibrations in the drive shaft not for balance.
CV Joint Service
• The joint is generally trouble-free unless
damage to the boot or joint goes unnoticed.
• CV joints encased in a protective boot.
• The boot retains the grease and keeps dirt
and water out.
• A torn or loose boot or clamp will allow
rapid wear of the joint.
FWD Inspection Points
Diagnosis and Inspection
• Popping or clicking when turning indicates
a possible worn outer joint.
• Clunking during acceleration, deceleration,
or going in/out of gear can be caused by a
worn inner joint.
• Humming or growling may be due to
inadequate lubrication.
CV Joint Service Tips
• Always follow manufacturer’s service
procedures.
• Never let the axle or other components hang
free.
• Be careful not to damage ABS sensor
components.
• Use the correct pullers to separate the inboard
joint from the differential.
CV Shaft and Boot Care Tips
• Do not use half shafts as lift points.
• Shield boots when performing brake,
suspension, or steering work.
• Clean only with soap and water.
• Avoid contact with gasoline, oil, or
degreasers.
Rear-Wheel Drive Shafts
• Must transfer torque while rotating, changing
length, and moving up and down.
• The U-joints permit variations of the angle of
drive and a slip yoke allows the length of the
shaft to change.
Operation of U-Joints
• Allows two rotating shafts to operate at a
slight angle to each other.
• Double-hinged joint connected to two shaft
yokes.
• Do not operate at a constant velocity or
without vibration.
• Vibration may be felt if the U-joint angles
are too steep or are unequal.
Phasing of U-Joints
• U-joints must be in phase with each other to
eliminate noise and vibration.
Diagnosis of Drive-Shaft
and U-Joint Problems
• A clunk when shifting into gear is a
common failure symptom.
• Vibration during acceleration and
deceleration that is less speed sensitive.
• Inspect pinion shaft seal for leaks
• Check drive shaft runout, angle, and inspect
for dents, missing weights, or other damage.
Purposes of a
Differential Assembly
• To transmit power from the drive shaft to
the wheels.
• To turn the power flow 90 degrees on RWD
cars.
• To allow the wheels to turn at different
speeds while cornering.
Hypoid Gears
• Contact more than one tooth at a time.
• Gear contact is a sliding motion which is
more quiet.
• Requires extreme pressure lubricants.
Gearset Classifications

• Hunting Gearset
– Any given tooth on the pinion gear contacts all
of the teeth on the ring gear before it meets the
same tooth again.
– The gearset does not have to be indexed.
– An example ratio is 3.73:1.
Gearset Classifications (cont’d)
• Non-hunting Gearset
– Each tooth of the pinion gear will come in
contact with the same tooth on the ring gear each
revolution.
– The gearset must be assembled with its index
marks aligned.
– An example ratio is 3.0:1.
Gearset Classifications (cont’d)

• Partial Non-hunting Gearset


– One tooth of the pinion gear will come in
contact with the same tooth on the ring gear
every other revolution.
– The gearset must be assembled with its
index marks aligned.
– An example ratio is 3.5:1.
Integral-Carrier Differential
Differential Operation

• The drive pinion drives the ring gear, which


is attached to the differential case.
• When going straight ahead:
– The differential housing and its components
rotate as an assembly.
– Power is transferred equally to both wheels.
Straight Ahead Operation
Differential Operation (cont’d)

• When turning a corner:


– The wheels must travel at different speeds to
prevent tire scrubbing.
– The differential pinion gears “walk” around the
slower side gear and cause the other side gear
to turn faster.
– The percentage of speed that is removed from
one wheel is given to the other.
Operation When Turning
Limited-Slip Differentials
• In a standard differential, if one wheel loses
traction, torque is lost to the other wheel.
• This can cause rapid wear of the gears.
• The limited-slip differential (LSD) are used
to reduce this traction loss by applying
torque to the wheel that is not slipping.
Axle Shafts
• Transfers torque from the differential
assembly to the driving wheels.
• Dead axles do not drive wheels.
• Live axles drive the wheels.
• Three types of driving axles are commonly
used:
– Semifloating, three-quarter floating, full-floating
Semifloating Axle Shafts
• Help support
vehicle weight.
• Supported by
bearings in axle
housing.
Three-Quarter Floating Axle
• The wheel bearing is on the outside of the
axle housing instead of inside as in a
semifloating axle.
• Wheel hubs are bolted to the end of the axle
shaft.
• Used on older vehicles and some trucks.
Full-Floating Axle Shafts
• Two bearings are
used to support
the hub.
• All stresses are
carried by the
axle housing.
Axle Shaft Bearings
• Support vehicle weight and reduce rotational
friction.
• Radial loads are always present.
• Thrust loads are present when driving.
• Three types of bearings are used:
– Ball bearings, straight roller bearings, and
tapered roller bearings
Diagnosis
• To diagnose drive axle or differential
concerns, operate the vehicle in these four
modes:
– Drive mode accelerates to apply torque
– Cruise mode holds speed constant
– Coast mode decelerates with closed throttle
– Float mode controlled deceleration
Diagnosis Tips

• If noises change with road surfaces, they


are not caused by the final drive unit.
• Drive axle and differential noises usually
change when accelerating and coasting.
• Bearing noises usually don’t change with
driving mode.
Assembly
• Align ring gear bolt holes to case before
pressing the gear on.
• Tighten ring gear bolts in steps.
• Locate gear teeth alignment marks.
• Check and set pinion gear depth.
• Set pinion bearing preload.
• Check and adjust gear backlash.
Common Contact Patterns
Maintenance
• Lubricating U-joints
• Inspecting and changing lubricant:
– Many rear axles use SAE 80 or 90 weight
meeting API GL-4 or GL-5 specifications
– Proper lubricant on limited-slip differentials is
very important to prevent damage to clutches
Diagnosing Differential Noises
• Whining when cornering:
– Possible damaged pinion gears and shaft
• Chuckle noises on deceleration:
– Excessive clearance between ring and pinion
• Knock or clunk:
– Caused by worn, loose, or broken parts
• Chatter from limited-slip while cornering:
– May need lubricant replaced

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