16

This sample chapter is for review purposes only. Copyright © The Goodheart-Willcox Co., Inc. All rights reserved.

Chapter

Rear Axle
Assembly
Construction and
Operation

Technical Terms

Solid-axle rear Spider carrier

suspension gears
Independent rear Side
suspension Differential gears
drive gears Drive Locking
pinion gear differential
Pinion bearing Limited-slip
Collapsible differential Clutch-
spacer Jam nut plate differential
Pinion shim Cone differential
Ring gear Ratchet differential
Wheel hop Torsen differential
Standard Hydraulic locking
differential differential Differential
Differential case carrier

Axle tube

Removable
Pinion pilot bearing Side bearings Integral carrier Solid drive axle Axle flange Full-floating axle

Axle bearing Axle collar Independently

suspended drive axle
Axle retainer plate Semi-floating axle Axle shim

309
310 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 311
Operation
engine and road. They are ruggedly
constructed and seldom fail. The most Inspection cover
Introduction common rear end failures are axle bearing
failures. A typical rear axle assembly is
shown in Figure 16-1. Bolt
The rear axle assembly is used on rear- In a rear axle assembly, engine power
wheel drive vehicles. This assembly is the enters the drive pinion gear from the drive Thrust Spider Side gear
final leg of the drive train. It is often called shaft assembly and differential pinion washer gear
the final drive or rear end. The rear axle yoke/flange. The drive pinion gear, which is in
assembly is often mistakenly called the Thrust washer
mesh with the ring gear, causes the ring gear
differential. The differential is only part of to turn. The interaction of the ring and drive
the rear axle assembly. pinion gears turns the power flow at a
The basic design of rear axle assemblies 90angle. The difference in the number of
has been adopted by all manufacturers for
many years. There are
several variations, but all operate according teeth on the ring and pinion gears causes a Retaining
Side
to the same basic principles. The major reduction gear Sid washer
Thrust bearing Shim
difference between rear axle assemblies ratio. This reduces turning speed, while e
washer Cup
depends on whether the vehicle has solid-axle increasing torque. Power from the ring gear gea
flows through the differential case, spider r Spider
rear suspension or independent rear Thrust
gears, and side gears to the drive axles. The gear
suspension. Solid-axle rear suspension Pinion washer
incorporates rigid and nonflexing drive axles drive axles transfer power from the differential
shaft
and axle tubes; both wheels move as one assembly to the rear wheels.
solid unit in response to bumps and The bearings and rear axle housing are
potholes. Independent rear key com-
suspension incorporates jointed drive axles (no ponents of the rear axle assembly. They are
axle tubes) designed to
that allow for flexibility and independent axle Pinion shaft Side
support and align the differential assembly
movement. This chapter is designed to identify lock pin bearing
and the drive axles. Notice that the bearings
and explain the con- struction and operation of Cup
and axle housing are large, heavy-duty parts. Bolt
various rear axle assemblies. The material in This is to ensure they will stand up under hard Shim
this chapter provides a basis for usage.
understanding how to properly troubleshoot Seals and gaskets are also very Differential case
Ring gear
and repair rear axle assemblies. important to the operation of the rear axle
assembly. Seals are used at the
differential pinion yoke/flange and at the outer drive axles.

Construction and Operation Gaskets are used at housing interfaces, such

as between the differential cover and the
Differential
cap
Overview Inspection cover housing, to provide a tight seal from the Drive
pinion Bolt Rear axle
outside. housing
Ring Figure
gear 16-2 is an exploded view of a common gear Pinion Differential
type of rear axle assembly. Notice the shim carrier
The rear axle assembly includes Side the
bearings
differential assembly, the rear drive axles, relationship of the internal parts to the Axle tube
and the rear axle housing. Rear axle housing and to each other. Note that the rear
assemblies are subjected to heavy loads from
the Differential
case

Drive axle
Pinion Pinion
Wheel, or Ring and
bearings bearing
axle, bearing pinion
assembly Pinion
Bolt bearing cup
Companion l cup
flange

Side gears Bea

ri
Drive Rear axle Pinion or n
axle housing spider gears g
Axle Drive Nut Sea
flange Axle seal pinion gear
310 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 311
Operation g o aring
n assembly
ill
Pinion spacer Pi
er b
n
pl e
u i
Pinion seal

Drive
axle Slinger
Pinion nut
Axle
bearing Pinio
Bolt Brake assembly n
flange

Figure 16-2. Exploded view of a rear axle assembly shown in Figure 16-1. (Ford)
Figure 16-1. Most rear axle assemblies contain the same parts as shown in this cutaway. Note that some drive axles differ from
this basic design. (Ford)
312
axle housing and drive axle designs will be
different when the vehicle has independent
rear suspension. Also, when
the rear axle assembly is equipped with a
limited-slip
differential, it will contain more parts. These
features will be discussed later in this chapter.
Differential Assembly
The differential assembly in a rear-wheel
drive vehicle has three functions. The first,
and most obvious, is to redirect the power
flow to drive the rear wheels. The power flow
must make a 90turn between the drive shaft
assembly and the rear wheels. This is
accomplished in the differential assembly by
the drive pinion and ring gears.
The second function of the differential
assembly is
to multiply engine power, reducing speed at
the output in the process. If there were no
gear reduction (1:1 gear ratio), the vehicle
would accelerate very slowly. In some cases,
the engine would be unable to move the
vehicle.
At the very least, gas mileage would be
harmed, since
the engine would not reach its most efficient
rpm range. For this reason, the ring and
drive pinion assembly, by design, provides a
reduced speed at its output. The reduction is
between 2:1 and about 5:1, depending on
the engine size, vehicle weight, and intended
use of the vehicle.
The third function of the differential
assembly is to allow the vehicle to make
turns. If the assembly did not make
allowances for the different speeds of the
rear wheels during turns, one tire would lose
traction with the ground as the vehicle
turned corners. The differential assembly
allows the vehicle to make smooth turns.
The differential assembly consists of
numerous parts, including the differential
drive gears (ring and drive pinion gears),
pinion bearings, differential case, spider and
side gears, and side bearings. See Figure 16-3.
These parts and their function are described
in detail in the following section.
Drive
pinion Side Side
Adjusting bearing gears
gear
nut
Differenti
al shaft
Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 313
Operation
Differential Drive pinion Drive pinion gear held to the drive pinion gear shaft by a large
pinion splines nut and washer that threads onto the shaft.
Pinio
n yoke This nut is a type known as a
preload shim Threads for Collapsible jam nut. The top threads of the nut are deformed
yoke nut spacer to tightly
Pinion grip the threads on the drive pinion gear
bearings
shaft. This is an interference fit. Tightening
the nut also adjusts the pinion bearing
Pinion depth shim
preload.
Rear axle Drive The pinion yoke is machined to accept
housing pinion gear
Ring
the bearing cups of the rear universal joint.
The cups are either pressed in and held with
gear snap rings, or they are attached to the yoke
with U-bolts or bolted-on straps.
Side
bearing Drive pinion Pinion flanges are simply a two-piece yoke
gear shaft Rear pinion joined by mating flanges. The outer section
bearing has the yoke; the inner section has the
external splines for the pinion gear shaft.
These companion flanges, as they are also
called, would be separated at the flanged
section to remove the drive shaft assembly,
Figure 16-7.
The position of the drive pinion gear
relative to the
Differential Figure 16-5. A typical drive pinion gear. The rear pinion
Side Differential ring gear must be set exactly. Otherwise, the
case bear- ing is pressed on the drive pinion gear shaft. A
bearing bearing shims
collapsible spacer is used to aid in pinion bearing installation. gears will be noisy and will wear out quickly.
(endplay/preload)
Threads and splines at the front of the drive pinion gear The position of the drive pinion gear in the
shaft are used for installing the differential pinion yoke. housing must be carefully adjusted so that it
(General Motors) contacts the ring gear at exactly the right
tooth
Figure 16-4. The positions of the drive pinion gear and the
ring
depth. To make this adjustment to the ring and
gear are always about the same. The two pinion bearings drive pinion
and two side bearings are always tapered roller bearings that The rear pinion bearing is pressed onto clearance, a pinion shim is installed in the
must be carefully adjusted. Some drive pinion gears have a the drive pinion gear shaft at the gear end. housing, behind the rear bearing cup. The
third bearing—a pinion pilot bearing—for support. Bearings The front pinion bearing is often a slip fit on thickness of this shim determines the depth of
and adjusting devices (shims or adjusting nuts) are usually
the smaller end of the shaft. The outer races, the drive pinion gear in the housing. This shim
located as shown. (DaimlerChrysler)
or bearing cups, of both bearings are pressed is installed at the factory when the rear end is
into the rear axle housing. assembled. It must be checked for proper
Differential Drive Gears Either a solid spacer or a collapsible thickness whenever the drive pinion gear is
spacer (crush washer) is used to set the removed.
The differential drive gears also called the pinion bearing preload. The collapsible spacer Figure 16-8 shows the position of the pinion
ring and pinion gearset, consist of the ring and is designed to be slightly compressed when shim on
drive pinion gears, Figure 16-4. These hypoid the drive pinion gear is installed in the rear most rear axle assemblies. This figure also
gears redirect power flow by 90and multiply axle housing. The spacer maintains a mild shows the rela- tive position of the
engine power. The number of teeth in the ring pressure between the front and rear pinion collapsible spacer.
gear compared to the number of teeth in the bearings, making it possible to accurately
drive pin- ion gear sets the rear axle ratio. For adjust the bearing preload. Ring gear
instance, if the ring gear has 40 teeth and The differential pinion yoke/flange has
the pinion gear has 10 teeth, the ratio is internal splines that fit the external splines on The ring gear, Figure 16-9, transfers power
40:10, or 4:1. The ring gear always has more from the drive pinion gear to the differential
the drive pinion gear shaft. See Figure 16-6.
teeth than the drive pinion gear. Rear axle case. Both the ring gear and the case are
The rear of the yoke/flange, where it fits into
ratios can always be determined by dividing the rear axle housing, is machined smooth. machined to fit together tightly. Bolts are
the number of teeth on the ring gear by the This is the sealing surface for the pinion seal.
number of teeth on the drive pinion gear. The yoke/flange is Drive shaft
nion gear gear is a
Dr hardened-steel
Ring gear T
iv he gear with an
Spider gears integral shaft,
e drive
pi pinio Figure 16-5. It
n is machined to
312 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 313
mesh gear ential bearin ine that of the ring gear. With this design, the Operation
Differential Drive
with has pinion gs, of pinion gear is placed lower in the rear axle pinion yoke Differential pinion gear Flange bolts
and externa yoke/fla called the housing. This is done seal surface
rotate l nge. pinion driv Splines lock
the ring splines The bearing e gear to yoke
gear. that fit gear is Pinion
s. pinio
gear nut
The end the support By n Companion
of the internal ed by Hole for
design gear flanges
U-joint
shaft splines two , the lies
opposit of the tapered axial belo U-joint
e the differ- roller centerl w Drive pinion Rear axle
Pinion bearing Case
Adjustin to lower the drive shaft and, therefore, the Flat washer gear shaft assembly
Side bearing drive shaft hump
g nut
in the vehicle passenger compartment. The
spiral design of
the gear teeth allows the gears to mesh Figure 16-6. The differential pinion yoke slides over the drive Figure 16-7. Some differential pinion yokes are two-piece
Figure 16-3. Relative positions of parts of a differential with a sliding pinion gear shaft and is secured by the pinion gear nut. The flanged assemblies, as shown here. This type of design is
assembly. The interaction of the various parts of the motion, creating a smooth power transfer. As tightening nut also preloads the pinion bearings. The outer sur- referred to as a differential pinion flange, or companion flange.
differential may be more easily understood by studying this a result of the sliding action, the gears must face of the drive pinion gear shaft seals against the front oil (Ford)
illustration. (Subaru) have a good supply of the proper lubricant. seal.
Gears of this type are called hypoid gears.
314 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 315
Operation
Rear pinion Differential Case Assembly Ring gear Case the outer wheel to turn at 110% of case speed, while
Differential Collapsible bearing
Side gears
the inner wheel turns at 90% of differential case speed.
pinion yoke spacer When a vehicle makes a turn, the outer These percentages will vary with the radius of the turn.
Pinion wheel travels a greater distance than the
gear nut
inner wheel—the arc (or radius) of the turn is
Locking differential
greater at the outer wheel. If the rear drive
axles were simply connected together, both The standard differential works well in most situa-
wheels would have to travel an arc of the tions. However, on very slippery surfaces, such as icy or
same length during a turn. Since this is muddy roads, lack of traction can cause the rear wheels
impossible, one of the tires would lose to slip. This is because the standard differential will drive
traction, or slip, during the turn. If the tire did the wheel with the least traction.
not slip, it would skip over the road surface. If one drive wheel is on dry pavement and the
This condition is called wheel hop. other is on ice or mud, the ring gear and differential
The purpose of the differential case case will drive the spider gears. However, the spider
Drive axle
Front pinion assembly is to allow the vehicle to make turns Drive axle gears will not drive both side gears. When the spider
without slippage or wheel hop. It does this gears are driven by
with an arrangement of gears that allows
the rear wheels to turn at different speeds. Two
basic types
Rear U-joint bearing Pinion
of differential case assemblies used to Spider the differential case, they will walk around the side gear
shim gears related to the wheel on dry pavement. As a result, the
accomplish this task are the standard
differential and the locking differential.
Figure 16-8. Pinion shim and preload spacer locations. Proper Figure 16-10. The basic components of a differential case
assembly. The ring gear is bolted to the case, and the spider
pinion adjustment is critical. The adjusting nut, preload Standard differential gears and side gears are mounted inside. On most differential
spacer, and depth shim are all critical to proper pinion A
The standard differential, also called a single- assemblies, side bearings are pressed onto the case. All
adjustment. (DaimlerChrysler)
pull differential, is composed of meshing spider differentials contain the same general parts.
and side gears enclosed in a differential case.
used to hold the ring gear to the case. The
See Figure 16-10. They transfer power to the drive axles and rear wheels.
bolts pass through holes in the case and are
The standard differential case is usually a Side gears are also called axle end gears.
threaded into tapped holes in the back of the
ring gear. one-piece unit. The ring gear is bolted to the Some heavy-duty differentials contain four spider
Since the ring and drive pinion gear teeth case. The case is usually made of cast iron. gears and two pinion shafts. In this design, there is a
Occasionally, it is made of aluminum. Side center hole in one of the shafts. The other shaft passes
must mesh accurately to transmit motion
bearings are usually pressed onto the case. through it. The side gears are splined to the drive axle.
without noise or damage, the position of the
The spider gears are made of hardened steel On some differentials, the side gears contain C-locks,
ring gear is important. Automotive tech-
nicians should be familiar with gear and are held in place by a steel shaft called which hold the axles in place. See Figure 16-11.
terminology that will be encountered while the pinion shaft. The pinion shaft passes The spider and side gears are bevel gears. Power
adjusting the differential assembly to obtain through the differential case and the center transfer through the bevel gears causes them to be forced
correct gear positions. The convex side, or of the spider gears. It is attached to the case away from each other. This causes high thrust forces on
drive side, and the concave side, or coast with a bolt. Spider gears are also called pinion the backs of the gears, where they contact the differential
gears. case. Hardened-steel washers are usually installed
side, of the ring gear are pointed out in Figure
Spider gears mesh with side gears, which between the back of the gears and the case. These
16-9A. These terms will be used when
differential gears are adjusted. The tooth are also made of hardened steel. When the washers provide a sliding surface and reduce wear. See
parts that must be carefully adjusted are ring gear and differen- tial case turn, the Figure 16-12.
spider and side gears also turn. Power flow is Figure 16-13 shows the operating states of the
identified in Figure 16-9B. The terms heel and
Heel Profile through the case, into the spider gears, and on differ- ential while driving straight ahead and while driving
toe will be used extensively for ring and
Top land into the side gears. The side gears are splined around a corner. In Figure 16-13A, the vehicle is moving
pinion gearset adjustment.
to the drive axles. straight ahead and both wheels are traveling at the same
speed. The spider and side gears rotate with the case but
Toe do not move in relation to it. The entire case assembly
Correct Lengthwise
bearing arc rotates as a unit.
pattern
Convex side Toe When the vehicle makes a turn, the axles and the
Heel
side gears begin turning at different speeds. The outer
(drive)
Concave side wheel— the left wheel, in the case of a right turn—turns
(coast) faster than the inner wheel, and the left side gear turns
faster than the right side gear. See Figure 16-13B. As
Root a result of the different axle speeds, the spider gears
begin to rotate. The left side gear, which is moving faster
than the right side gear, drives the spider gears, causing
B
them to rotate on, or walk around, the right side gear.
314 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 315
spider gears drive the slipping wheel, and the vehicle The two most common types of limited-slip Operation
Motors brand name dating back to the 1950s. differential is shown in Figure 16-15. The most
will
not move. The standard differential sends almost all differential are the clutch-plate differential and the Due to their complexity and higher cost, limited- obvious difference between this limited-slip differential
engine power to the slipping wheel. cone differential. The clutch-plate differential uses slip differentials are used only on high performance and a standard differ- ential is the clutch packs placed
To overcome this problem, locking differentials several fric- tion discs that look like small manual versions of rear-wheel drive automobiles. Limited-slip between the side gears and the differential case.
are used. Locking differentials overcome traction clutch discs. The cone differential uses a cone-shaped differentials are commonly found on modern trucks The clutch friction discs are made of steel covered
problems by sending some power to both wheels, clutch that engages a matching cone-shaped and SUVs. Many SUVs and some trucks have limited- with a friction material. The clutch plates are made of
while allowing the vehicle to make normal turns. receptacle. Limited-slip differen- tials have various slip differentials on the front and rear axles. Some steel. The discs and plates are alternately splined to the
There are several different types of locking brand names, including Positive Traction, Sure-Grip, companies make aftermarket limited- slip differentials side gear and dogged (meaning tabs fit into grooves) to
differentials, including limited-slip, ratchet, and Anti-Spin, Traction-Lok, and TXT. Many technicians to replace original equipment designs or to convert the
Torsen differentials. refer to limited-slip differentials as Positraction standard differentials to limited slip units.
differentials, although this is actually a General An example of a common clutch-plate
Figure 16-9. When installed, the ring gear is bolted to the differential case and meshes with the drive pinion gear. A—The ring Note that the differential case speed on turns is the differential case, Figure 16-16. Grooves in the discs or
gear has convex and concave sides. The convex side is the drive side. It contacts the drive pinion gear when the vehicle is average of the side gear speeds. This is because one plates are for better grabbing power.
accelerating. The concave side is the coast side. It contacts the drive pinion gear when the vehicle is decelerating. B—Gear side gear is rotating faster than the case and the other Figure 16-17 shows the moving parts of a clutch-
terminology will be important when the differential assembly is serviced. Proper heal and toe contact is critical to quiet side gear is rotating slower than the case. In Figure plate differential. The spider gears, side gears, and
operation and long life. (General Motors, DaimlerChrysler)
16-14, when the vehicle makes a turn, the action of the other parts are very similar to those used in a standard
differential allows differential. The
 2
1 3
316 Manual Drive Trains and Axles ChapterSide
16 gear
Rear Axle Assembly Construction
Thrust and 317
4 Operation washer
5
Spider gear
Figure 16-14. The speed of the differential case on turns is
10 6 the average of the side gear speeds. (DaimlerChrysler)
Thrust
washer Lockpin
7
11 C-lock differential case of the limited-slip differential is often
made in two parts to allow for clutch pack removal, as
Figure 16-12. This is an exploded view of the differential
shown in Figure 16-18.
8 gears. Note the relationship
Pinion of the side and spider gears to
The discs and plates are applied by the preload
each other. Also shaft
note the thrust washers that separate the
12 gears from the case and the C-lock that holds the axle shaft springs and by the mechanical pressure of the spider gears
9 in place. The pin- ion shaft is held in place by a pin that on the side gears. Since the spider and side gears are bevel
passes through both the shaft and differential case. gears, their teeth try to come out of engagement when the
17 (DaimlerChrysler) differential is transmitting engine torque. This creates a

21 16
20 Driving Driving
straight ahead around corner

Pinion
gear drives

25 Side gears
23 and drive Left drive
axles turn axle turning
19
1. Drive coupling
24 8. Rear pinion bearing 15. Lock screw 21. Drive axle same on faster
18 both sides Spider gears
2. Thrust washer 9. Pinion depth shim 16. Pinion 15 22. Drive axle C-lock
3. Lock nut 10. Differential carrier 17. Thrust washer
gear 22
23. Bearing cup bolt Spider gears Side gear now turning
4. Oil seal 11. 13
Ring gear 26 18. 14
Side gear 24. Bearing cup locked, assembly and drive Right drive
5. Drive pinion gear 12. Differential case 19. Side bearing 25. Differential cover gasket rotates as Ring gear axle axle turning
6. Front pinion bearing 13. Ring gear bolt 20. Shim/spacer 26. Inspection cover A solid unit driven B slower
7. Preload 14. Pinion
spacer shaft
Figure 16-13. Differential action is shown here. Note the use of four spider gears, rather than the regular two. A—Straight ahead:
Figure 16-11. A section view of a typical differential contained in rear axle assembly. The differential case is installed in the rear Differential case gears turn as a unit. Both the drive axles and differential case are turning at the same speed. B—Right turn: The
axle housing. The ring gear, which is attached to the differential case, meshes with the drive pinion gear. The relative positions left axle is moving faster than the right axle. The left side gear drives the pinion gears. The pinion gears turn and walk around the
of the parts are similar on all differentials. Note the C-locks on the differential side gears. They retain the drive axles in the right side gear. Note that the differential works the same way for a left turn, except the action of the left and right sides is reversed.
housing. (General Motors) (Deere & Co.)
318 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 319
Operation
Preload Ring gear Steel plates External Ring gear Power in
Belleville
spring mounting surfaces with external tabs splines mount Differential from drive
spring
case Differential shaft assembly
Differential components
side gear
Multiple-disc Drive axle Spider and side
clutch sets Pinion gear
installs here Drive axle gears rotating with
drives
installs here case as a unit
ring gear
Equal
rotation
Differential of both
case
axles
turning
Differential
Friction discs side gear
with internal teeth Side
Side bearing
Differential Figure 16-16. Exploded view shows the clutch pack of a
limited-slip differential. Each clutch pack has the same number bearing
spider gear Parting line
Differential of clutch discs and plates. Note the internal teeth on the
friction
case discs and the external tabs on the steel plates. Grooves in Figure 16-18. The differential case of a limited-slip differential
the
is often made in two parts. Note the parting line on the case of Axles splined Clutch packs
Figure 16-15. Study the assembled view of the clutch-plate discs and plates reduce the chance of
this limited-slip differential. (DaimlerChrysler) to side gears inoperative
differential. The clutch packs are sandwiched between the slippage. (DaimlerChrysler) A
side gears and differential case. The preload spring applies
initial force to the clutch packs but still allows enough slippage pushing action on the side gears, forcing
in the clutch pack for normal differential operation. (Ford) them outward against the differential case. Friction in clutch
Power in
The outward pressure of the side gears from drive packs transfers
presses the friction discs and steel plates shaft assembly power from
together between the side gears and the case to side
Case case. Whenever the discs and plates are gears
Case drives
pressed together, the splined and dogged
clutch pack
connections ensure the side gear and
Ring gear differential case are locked together.
The operation of a clutch-plate differential
is shown in Figure 16-19. When the vehicle is
moving straight ahead, the clutch-plate
differential operates in the same manner as a
standard differential, Figure 16-19A. The rear
wheels and the differential case turn at the Large torque
Side gear same speed. The clutch packs are applied, output to Small
but they are not needed. drive wheel torque
When turning, the vehicle loses traction at output to
one wheel, causing the wheel to slip, Figure Clutches splined drive wheel
Thrust block 16-19B. Since the wheel is slipping, the spider
B to axle gears Spider gears
gears do not press tightly on the side gear of rotating
the slipping wheel. The side gear also does
Snap ring not press toward the case, and the clutch pack
Spider gear Thrust washer
of the slipping wheel is not pressed tightly
together.
Belleville Since there is a normal tendency for the
spring
side gears to move away from the spider
gears under load, the other
Retainer clip side gear moves outward and away from the
Pinion shaft spider gears. The side gear is under load
Clutch pack
because its related wheel has traction. The
pressure on this side gear causes the related
Figure 16-17. This shows the relative positions of the clutch
clutch pack to be pressed tightly together. The
packs, spider gears, and side gears of the limited-slip
differential. Notice the similarity to the standard differential. side gear is locked to the case by the clutch
(DaimlerChrysler) pack, and power is deliv- ered to the wheel with
traction.
318 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and
The clutch pack is designed to slip when some preset torque value is reached. When the Figure 16-19. StudyOperation
the action of the limited-slip
vehicle is making a turn, a high torque, caused by the outer wheel rotating faster than the differential. A—Traction on both wheels. The differential
case, causes the clutch pack to slip. This allows the dif- ferential to operate in the same parts are locked together and rotate as a unit. The clutch
manner as a standard differ- ential when making turns. The discs and plates slide against packs are not operating. B—One wheel is slipping.
each other—discs turning with side gears, plates turning with case—allowing different Pressure on the side gear of the wheel with traction
rotating speeds between case and side gears and, therefore, between rear wheels. causes the discs and plates of the related clutch pack to
grab, sending most of the engine power to that wheel.
Figure 16-20 shows a cone differential,
319
which is another version of the limited-slip
differential. In place of clutch packs, friction-
lined cones are used. The operation is similar
to that of the clutch-plate differential.
Preload spring and side gear pressures force
the cone into a dished depression in the
differential case. Friction tries to lock the cone
and, therefore, the side gear to the case,
sending
320 Manual Drive Trains and Chapter 16 Rear Axle Assembly Construction and Operation 321
Axles
Differenti
al clutch on the L/H R/H Driven Driven
side of the clutch and c
S wheel with the center l
i drive u
least traction.
d member t
e An example of
the ratchet are locked c
differential is and rotate h
g
at same
e shown in Figure
a speed. e
16-22. For l
r straight-ahead L/H side
s R/H side e
driving, both v
sets of teeth a
are t
e
d

b
y

c
a
m
s

a
n
d

t
r
a
v
e
l
s

a
t
f
a
s
t
e
r
s
p
e
e
d
.

P eng g L/
i age H
d,
and
the si
diff d
ere e
ntia g
l e
C cas a
o e r
and
wh
eels
R traction. Figure 16- The A B
/Lubr L special 21 is Torsen C
icati u Bot Driven Driven
br gear oil, differential is
on h clut clutch
ic a locking Figure 16-22. The ratchet differential uses
pock ati but it is ch and differential
et o often d elev center matching sets of teeth on each side of the
n using differential case. Teeth are engaged and
rough r ate drive complex
gr disengaged to transfer power. A—Differential
and noisy i d member
o worm is straight-ahead operation. Teeth are
ov in opera- v by are
gearsets. engaged on both sides of the case, and
es tion. It is e ca locked
n ms and The gearsets power is transferred equally to each wheel. B
usually include —When the vehicle makes a left turn, the
and rotate at
used in c trav same worms (drive greater speed of the right wheel causes the
off-road l els speed. gears) and internal cam on the right side of the case to
and u at worm wheels take the right-side teeth out of engagement.
racing t fast (driven All power goes through the left axle and
vehicles. c er wheel. C—When the vehicle makes a right
gears). The
h spe turn, the greater speed of the left wheel
Torsen differ- causes the left-side cam to take the left-side
e ed. ential has
s teeth out of engagement. All power goes
been through the right axle and wheel. (Ford)
available
a
n since the
d 1960s as a
high-
c performance
e replacement
n unit for
t standard
e differentials.
r It is now
d
being
r
offered as
i
v original
e equipment
on some
m European
e cars. The
m basic
b mechanical
e principle of
r this
t
differential
r
a
is that while
v the worm
e can drive
l the worm
a wheel, the
t worm wheel
s cannot drive
a the worm.
m an exploded view vibrate during operation that can be
e of the cone turns. depends on engaged and
differential. The rel- ative disengaged. This
s
p
Note that both ratchet wheel kind of engag- ing
e clutch-plate and differential, speed, teeth system is
e cone differentials nicknamed a rather than sometimes called
d require special Detroit locker, on wheel a dog clutch. The
. limited-slip gear uses a series traction. The series of cams and
oil. Using ordinary of cams and ratchet ramps disengage
Figure 16-20. Study plate differential. pressed into the dished area of the differential
the construction of the Pressure on the case, locking the case to the drive axle on that gear oil in limited- ramps to differential the teeth of the
cone differential. The side gear of the side. (DaimlerChrysler) slip differentials direct power transfers dog
operation of this limited- wheel with will cause the to the wheel power
slip differential is similar traction causes discs and plates or with the most through a
to that of the clutch- the cone to be power to the wheel with the most cones to slip and traction. Its set of teeth
 Worm W
As shown in During speed wheel as T mp resembles a
(axle gear) or
Figure 16-23, the straight- change is pressure. This h rotor-type engine
m
Torsen differential ahead transmitted pressure wh e oil pump, with a
has operation, from the increases the ee six-point external
two central the faster axle amount of power ls p gear that turns
worms. For differential to the sent to the slower u inside of an inter-
purposes of assembly slower one axle gear and Figure 16-23. nal gear with
clarity, these will operates like by the axle. It does not The Torsen seven cavities.
be referred to as a standard action of turn the axle differential uses The spaces
axle gears. One differential; the gear, but it does a unique between the
axle gear is all internal meshing allow it to turn Figure 16-21. Exploded view of the cone arrange- ment pump internal
attached to each gears turn as spur gears. with more force. differential shows the relationship of parts. of gears to and external
axle shaft. Worm a unit. When The Grooves in the cones help to solidly engage transfer power. gears are filled
wheels ride on the case. (DaimlerChrysler) This differential with gear oil at
the vehicle is axle gear Hydraulic has been
and are driven by making a on the all times. When
Locking available as a
the axle gears. turn, or when faster axle the gears move
The worm wheels Differentia high-
in relation to
one drive can drive performance
are held in place wheel is the respec- ls each other,
aftermarket
by the differen- slipping, the tive worm Some late replacement for spaces on the
tial case. Spur relative wheels. model SUVs have about 25 years. intake side of the
gears machined speed of the This driving locking It is now being pump open and
on the ends of drive wheels force is differentials that offered as draw in gear oil.
the worm wheels and, transferred are operated by original The fluid is
mesh and form therefore, of from the hydraulic equipment on carried around to
the only pressure. It may some European the output side of
the axles, spur gears
connection vehicles. The
changes. This on the be called a the pump, where
between the two operation of this
faster Hydra-Lock, Vari- the spaces begin
differential is
axle shafts. turning lock, or Georotor to close. Closing
complex.
Engine power Axle shaft worm system. A (Torsen) the
drives the wheels to hydraulic locking
differential case, the spur differential
and the worm gears on consists of a
wheels, held by the slower pump with
the case, turn Spur gears
turning internal and
with it. The worm worm external gears, a
wheels cannot wheels. ring-shaped
turn the axle Engine pressure
gears, so they power is diaphragm, and
lock themselves transferred a clutch pack
to the gears. In from the that resembles
this way, power faster to the clutch pack
is transmitted; the slower used in a con-
the axle gears worm ventional locking
and axles are wheels by differential, Figure
locked to the the 16-24A. The gear
case, and they Axle
interaction oil that operates
rotate with it. of the the hydraulic
gears. The system comes
Pinion thrust washer Clutch cone/ Spider gear worm from the
Clutch cone/ rear axle
Case side gear wheel on assembly
side gear Case
sump.
Spring the slower SpringSpecial
block oil is not
side still needed. The
cannot same oil is used
drive the for rear axle
slower axle lubrication, and
gear, but it the hydraulic
can trans- system does not
fer the have to be sealed
increased from the other
power from rear axle
the fasterPinion components.
shaft Spring Differential c a shaft se
block
322 Manual Drive Trains and Axles
each other, producing hydraulic pressure. This
pressure is delivered to the ring diaphragm,
which expands against the clutch pack. With
the clutch pack applied, the side axles lock
together and turn as a unit. When the wheels
begin turning at the same speeds, the internal
and external gears do not move in relation to
each other, and no pres- sure is produced.
With no pump pressure produced, the ring
diaphragm depressurizes and releases the
clutches. If one wheel again begins to slip, the
pump starts operating again, and the system
reapplies the clutches.
When the vehicle makes a turn, the pump
gears move
Chapter 16 Rear Axle Assembly Construction and 323
Operation
The rear axle housing associated with solid-axle rear
suspension consists of a central housing, or differential
carrier, and axle tubes, which enclose the drive axles and
extend to the rear wheels. (Vehicles with independent rear
suspension will not have axle tubes.) Rear axle housings
will have a vent to relieve pressure buildup. They will also Fill plug
have oil drain and fill plugs. See Figure 16-26.
Most rear axle housings are made of steel. Steel axle Drain plug
tubes are pressed and welded into the housing or are cast
integral with the housing. The axle tubes usually have an
integral flange at the outer end. The flange provides a Rear axle

slightly in relation to each other. They do not, mounting surface for the brake backing plate and an axle housing Drive shaft
however, pro- duce enough pressure to apply retainer plate.
A Figure 16-26. Rear axle assemblies will almost always have fill
the clutches. Therefore, the differential does Since the rear axle housing is a solid structure, it
plugs but not necessarily drain plugs. On a differential without
not attempt to lock up during normal turns. moves up and down with the wheels as they move over
Close fit seals a drain plug, the inspection cover or carrier must usually
Housing inlet and outlet
Some locking differentials are operated by bumps and holes. To control this movement, the rear axle
be removed to drain the oil. Oil can sometimes be drained
sides an electric motor attached to the axle housing is attached to the vehicle body through an by removing the lowest inspection cover-attaching bolt.
Outer assembly. Note the additional parts installed arrangement of springs, shock absorbers, and control arms, (DaimlerChrysler)
rotor Inner rotor on a standard rear axle, Figure 16-25. The shift Figure 16-27. These parts align the rear axle assembly to
Low High fork shaft and shift fork are operated by the the vehicle while isolating most of the axle movement.
motor and move a hub sleeve. The hub
sleeve has splines that can engage matching
splines on the differential carrier and side
gear.
pressure pressure During normal non-locking operation, the shift
area area fork shaft and
shift fork are positioned to keep the hub
sleeve disengaged. The hub sleeve has no
effect on differential operation.
To lock the differential, the motor moves
the shift fork shaft and shift fork to engage the U-bolt
hub sleeve splines with the splines on the Rear Vent hose assembly
differential carrier and side gear. The splines axle
lock the hub sleeve, differential carrier, and housing
side gear into a single unit. Locking the carrier
and side gear together prevents the other
differential gears from turning. The differential
assembly turns as a unit, delivering equal
power to each drive wheel.

Brake assembly
Inlet
Rear Axle Housing: Solid- Axle flange

Outlet Axle Rear Suspension

B

Figure 16-24. A—A hydraulic locking differential, consisting of a

The rear axle housing contains and the blies.
pump with internal and external gears, a ring-shaped pressure rea Differential
diaphragm, and a clutch pack. B—The arrangement of the supports other parts of the rear axle assembly. carrier
It also forms a reservoir for the rear end r Drive
internal and external rotor resembles a rotor type engine oil bra shaft
pump. The close fit of the inner and outer rotors forms a seal lubricant. The housing accommodates sus-
pension system attachment. Most rear axle ke
at the point where the teeth almost touch in the pumping
ass
chamber. (Daimler Chrysler) housings also support the stationary parts of
em
322 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 323
Operation Brak e line Brake drum

Shock
spaces produces pressure that can be used to absorbers
operate the other components of the
differential assembly. Figure 16-24B shows the
operation of a rotor-type pump. Check valves
ensure that pressure is always produced, no
matter what the direction of pump rotation.
The internal gear is attached to one of
the side axles. The external gear is attached
to the other side axle. When both wheels Motor

have equal traction, both side axles turn at Suspension

the same speed. Therefore, the internal and A system leaf spring
external pump gears do not move in relation
to each other, and no pres- sure is
developed. When the vehicle loses traction
to one
wheel, one of the side axles begins turning at
a faster rate
than the other. The difference in axle speeds Figure 16-27. Two methods of suspending the rear axle assembly of a vehicle with a solid-axle rear suspension are shown. Both
causes the internal and external pump gears methods involve the use of conventional shock absorbers. A—Leaf springs support and align the rear axle assembly. This method
to move in relation to simplifies the assembly, but makes the removal of the rear end difficult.
Figure 16-25. Rear locking differential. (Toyota) (continued)
324
Shock absorber
Control arm
Lock washer
Shims Locknut
Washer
O-ring
Oil seal
Axle, or
wheel bearing
B Brake assembly
Figure 16-27. (continued). B—Coil springs require the use of control arms and sway bars to maintain alignment. This method makes
for easier rear end removal. (DaimlerChrysler)
Leaf springs support the axle and hold it in
alignment, eliminating the need for control
arms, Figure 16-27A. When coil springs are
used, separate control arms must be used to
maintain rear axle alignment. See Figure 16-
27B.
Two kinds of rear axle housings are used
on vehicles
without independent rear suspensions—
removable carrier
and integral carrier. Both types will be
discussed in this
section. (Rear axle housings used with
independent rear suspension will be discussed
in the section that follows.)
Removable Carrier
The removable carrier has a separate
housing for the
Manual Drive Trains and Axles Chapter Rear Axle Assembly Construction and 32
16 Operation 5
Carrier the rear axle housing. Most of these can be
Suspension system Side bearing bore
mounting
coil spring removed through the opening that is kept
flange
closed off by the inspec- tion cover. The cover
is sealed with a gasket of some sort.
The pinion front and rear bearing cups
Bearing bore are pressed into the carrier portion of the rear
Rear axle
housing axle housing. Integral carriers do not normally
have a pinion pilot bearing.
Differential side bearings are installed in
Side bearing the integral carrier in the same manner as on a
Sway bar removable carrier. The side bearing preload
adjustment is sometimes made with shims.
These shims are placed between the bearing
Outer race cup and the rear axle housing. In other
instances, the preload
Pinion bearing Carrier adjustment is made with a threaded end
Inner race
Bearing housing cap, as on the removable carrier.
Axle flange Figure 16-29. The mounting flange of a removable carrier is
Brake drum designed to seat against the axle portion of the rear axle
housing. The carrier is attached with studs and nuts. The
gasket is always installed between the carrier and the axle Rear Axle Housing:
housing. (Subaru) Independent
Rear Suspension
Oil seal differential side bearing mounts have a
provision for adjusting the side bearing
preload. This adjustment is usually made with On vehicles having independent rear
a threaded end cap, or adjusting nut. The suspensions, a modified rear axle housing is
end cap is tightened against the bearing cup used. Figure 16-32 shows such a housing.
until the proper preload is attained. Notice that the housing has no axle tubes. The
Drain and fill plugs may be mounted on drive axles resemble drive shaft assemblies
the differen- tial carrier or on the rear axle to some degree, complete with conventional
housing, depending on the particular or constant-velocity universal joints. This
manufacturer. The ribs on the front of the design allows each wheel to react
carrier strengthen it without adding a great independently to the road surface, improving
deal of weight to the assembly. ride quality and handling.
The housing has oil seals to prevent oil loss
and tightening nuts over the threaded studs. where the axles enter the housing. The
This attaching method makes it easier to align Integral Carrier internal construction of the housing is identical
and reinstall the carrier. A gasket is always to the previously discussed carriers. To reduce
The integral carrier, as the name implies, is
used between the carrier and axle housing. vibration and strengthen the drive train, a
an inte- gral part of the rear axle housing. See
The differential pinion bearings are installed torque tube is sometimes used to attach the
Figure 16-30. This type of rear axle housing
in the front of the housing to one of the vehicle
has a sheet metal or cast metal
crossmembers. (Torque tubes were explained
in Chapter 12.)
carrier in the pinion bearing bores. When inspection cover, sometimes called the differential cover.
tapered roller
bearings are used, the bearing cups are tightly The inspection cover can be removed to Rear Drive Axles
pressed into service the rear
the bores. Some removable carriers have an end components. Service operations must be performed
extra support
bearing at the end of the pinion gear. This under the vehicle, since the carrier cannot be
separated The rear drive axles transfer power from
bearing is called a pinion pilot bearing.
from the rest of the rear axle housing. the differen- tial assembly to the rear wheels.
Figure 16-29 shows the attaching points for
Figure 16-31 shows a typical integral There are two major kinds of drive axle
the differ- designs. One is the solid drive axle, shown in
carrier. Notice that almost all the rear end
ential side bearings, also called case bearings.
The side bearings are held in place by bolted,
components are installed inside Figure 16-33; the other is the independently
suspended drive axle, shown in Figure 16-34.
U-shaped caps. Most
Drive pinion
differential assembly, Figure 16-28. It can be unb olted and removed from the rest of the rear axle housing
324 Manual Drive Trains and Axles Chapter Rear Axle Assembly Construction and 32
after the drive axles are removed. All of the Drive 16 Operation 5
Axle tube gear Integral carrier
internal differential parts, then, will be pinion gear Removable Solid Drive Axle
removed with it. Differential assemblies carrier
housed in this kind of carrier are, in general, A solid drive axle, or live axle, is a hardened-
easier to service, since repairs can be done on steel shaft. See Figure 16-35. Each rear axle
Ring gear assembly in solid- axle rear suspension
the bench instead of on the vehicle.
The carrier mounting flange is where Ring Gasket surface systems has two. External splines on the
the carrier Rear axle gear inboard (inner) end of each axle mate with
attaches to the rest of the rear axle housing Inspection cover internal splines on the differential side gear to
housing. Usually, Axle tube which it is connected. An axle flange at the
outboard (outer) end of each axle acts as a
wheel hub. It provides the mounting surface
for the
threaded studs are installed in the housing. Figure 16-30. The rear axle housing with an integral carrier is brake drum or rotor and the wheel. The brake
Figure 16-28. The removable carrier type of rear axle housing essentially a one-piece unit. All moving parts are inside
The studs pass through holes in the mounting assembly and
is a two-piece assembly. The carrier contains differential parts. the housing. The differential parts are reached for service by
flange when the carrier is installed. The carrier It can be unbolted and, after the drive axles are removed,
wheel are installed directly on the flange wheel
removing the inspection cover at the rear. This type of axle studs.
is then tightened in place by installing serviced on a bench. is usually serviced under the vehicle.
Each shaft is supported on the outboard
end by an
axle bearing, also called a wheel bearing. The
axle
326 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 327
Operation

Axle flange Pinion

yoke Nut
Screw
Cup

Collapsible spacer
Differential
Seal carrier
Washer
Independent
Seal
rear suspension
Axle bearing
Cone and rollers
Axle flange

CV-joint
Torque tube
Axle tube Drive axle
Drive shaft
Adjuster Bolt Crossmember

Washer Cap Shaft

Lock Cup Axle Seal
Figure 16-32. The rear axle housing used on vehicles with independent rear suspension has no axle tubes. The carrier has oil seals
bearing
where the drive axles enter. A torque tube is often used at the front of the housing to increase rigidity and reduce vibration.
(DaimlerChrysler)
Case Shim Stud
Ring and pinion
Bolt drive gears Cup
Cone and
rollers
Lock
Screw

Lock Cone and rollers

Washer Drive pinion

Side gear Adjuster
Washer gear

Differential
Axle tube assembly
Pinion Solid drive
Lugs axle
Plug Side gear Washer Splined
Cup
Washer connections
Screw Cap
Inspection cover Screw

Figure 16-31. This is an exploded view of an integral carrier rear axle assembly. Notice that most of the moving parts fit inside the
rear axle housing. The inspection cover often contains a fill plug. (DaimlerChrysler)

bearing can be installed on the shaft or in the axle tube.
Axle bearings that are installed on the shaft are
usually packed with grease. An axle seal is pressed into the
housing behind, or on the inboard side of, the bearing. The
lip of the seal seats against a machined area of the shaft.
This seal keeps rear end lubricant from reaching the bear-
ing. An outer seal prevents water and dirt from leaking
through the outer ends of the rear axle housing and enter-
ing the bearing.
Axle bearings that are installed in the housing are
lubricated by rear end lubricant (gear oil). When the vehi-
cle makes a turn, lubricant is thrown outward from the
car-
rier, reaching the axle bearing. An axle seal is installed in
Axle
lubricant from leaking out from the outer ends of the rear flang Spider and
Inspection
axle housing. The shaft is held in place by a clip as e Axle side gears
cover
explained in the next section. bearing
Ring gear
An axle bearing installed on the shaft is held in place
by an axle collar. The axle collar is tightly pressed on the
shaft. In addition, some will have a spacer to keep the
bearing at the proper distance from the end of the axle.
The axle retainer plate holds the axle and axle bearing to
the axle tube.
Semi-floating axles
Solid drive axles can be semi-floating or full-floating.
front of, or on the outboard side of, the bearing to keep Most automobiles and light trucks have semi-floating
326 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 327
axles. In the semi-floating axle, the weight of the vehicle Figure 16-33. The axle shaft used on a solid drive axle, or a Operation
outer support is provided by an axle bearing, and an inner support is provided by the differential side bearings. Note that the
live axle, is a single piece of steel that is supported on both differential has been rotated 90for the purpose of illustration. (Fiat)
ends. The
328 Manual Drive Trains and Axles Chapter Rear Axle Assembly Construction and 32
16 Operation 9
Brake backing plate housing, depending on the particular
manufacturer’s design. In Figure 16-36C,
Rubber seat Axle retainer notice the use of the tapered axle.
plate Seal Axle This is one of two methods used to secure a
collar wheel hub to its axle. The tapered end wedges
Insulator
Coil spring into a tapered hole in the wheel hub, and the
Differential Axle
mounting flange Axle key keeps the axle from rotating in the hub.
Bumper rubber
insulator supports The other method, mentioned earlier, has the
Differential and drives wheel hub (axle flange, in this case) solidly
assembly Dust cover wheel mounted to the axle. The design of the semi-
floating axle causes weight loads to be placed
on the axle. These loads will shift as the axle
rotates, placing flexing stresses on the shaft.
On auto-
Real mobiles and light trucks, the loading is not
Retainer-to- Axle serious and the
axle
housing seal
Drive housing axles will usually last the life of the vehicle.
bolt
axle
Axle bearing
Shock A—Ball bearing semi-floating axle. The ball bearing is retained on Full-floating axles
absorber shaft by a pressed on axle collar. The bearing and axle are held in If the rear end will be subjected to heavy
the housing by a bolted retainer plate.
loads, such as the rear end of a large truck
Disc rotor might be, a full-floating axle is used. Figure
Rear axle housing 16-37 shows an example of a full-floating
axle. With this design, the axle drives the
wheel but does
Axle Brake backing not carry any of the vehicle weight. The
bearing plate weight passes through the bearings on the
wheel hub. The wheel hub absorbs the
Stabilizer Wheel stresses. This design reduces the stresses on
lug stud
the shaft, prolonging its life. Full-floating
Suspension arm
Drive axle axles are not used on light duty vehicles
because of their extra cost and complexity.

Suspension
member stay
Gear oil Independently Suspended Drive
Figure 16-34. Axle shafts used on vehicles having independent rear suspensions somewhat resemble drive shafts. A flexible joint, Axle
such as a CV joint, is used on each end of each shaft. Axle Axle Independently suspended drive axles, used on
flange housin vehicles with independent rear suspension,
g seal resemble miniature drive shaft assemblies.
The axle consists of a central shaft with
flexible joints and stub axles on each
passes through the axle bearing to the drive B—Roller bearing semi-floating axle. The major difference between end. The flexible joints—either cross and roller U-
axle and on to
Axle this design and that of ball bearing is the shaft locking method. This joints or
the wheel and tire. Figure 16-36 shows three
retainer axle is retained by a C-lock at the inside of the shaft. The C-lock
versions of the semi-floating axle. attaches axle to the differential. The bearing plays no part in keeping
plate Figure 16-36A shows a semi-floating axle the shaft in place. Hub, not axle, supports
using a ball
Shaft bearing. This is a pregreased bearing. There is Drive wheel weight of car
inner Axle
an axle seal behind the bearing. The axle Brake backing plate Axle
bearing
collar is pressed onto the axle
sea shaft. The bearing and axle are held in the Ring seal Rear axle housing bearing
l housing by an Axle bearing
axle retainer plate, mounted on the outer end Washer Key
of the rear axle housing. The retainer plate
and bearing control end- play during turns. Nut Drive
Axle seal axle
Seal Figure 16-36B shows a roller bearing version
retaine Axle of the
r semi-floating axle. This bearing is lubricated
by rear end
aft lubri The is installed in front of the bearing.
collar cant axle
S . seal When this kind of bearing is used, the axle is held in the
Axle shaft h
328 Manual Drive Trains and Axles Chapter Rear Axle Assembly Construction and 32
housin the d nd of the shaft, at the dif- ferential assembly. 16 Outer
Operation 9
Tapered axle retainer Bolt Axle bearing
g by a inb This kind of axle is sometimes called a
supports wheel plate Washer
clip on oar e hub and
C-lock axle, because of the shape of the drives wheel
outer Endplay Axle
Axle flange seal locking clip. Endplay on turns is controlled by adjusting axle Sleeve nuts housing
the fit of the axle shaft shims
(wheel hub) between the C-lock and the other parts of the C—Tapered roller bearing semi-floating axle. The bearing preload retain bearing
differential is adjusted by shims or an adjusting nut. The axle is retained in Wheel hub supported
Figure 16-35. Drive axle and related components are shown assembly. same manner as ball bearing, except without the axle collar. The Wheel hub by bearings on
here. The external splines on the inboard end of the axle mate Figure 16-36C shows a semi-floating axle shoulder on the axle keeps the axle from sliding past the bearing. axle housing
using a tapered roller bearing. This type of
axle is usually found on
with the matching internal splines in the differential side gear. older vehicles. When this type of bearing is Figure 16-36. The semi-floating axle is the most common
The axle flange is a mounting surface for the brake drum Figure 16-37. The full-floating axle is used on trucks and
used, there is usually some provision for shaft and bearing design used on cars and light trucks. The
or rotor and wheel. The bearing is kept in place by the axle other vehicles that carry heavy loads. Bearings on the hub
adjusting the bearing preload to control bearing passes the vehicle weight through the axle shaft and transmit the vehicle weight from the rear axle housing to the
collar. The axle retainer plate keeps the axle and bearing endplay. This is generally done by using axle out to the wheel. The axle drives and supports the vehicle. wheel hub and the wheel without the loading axle. The only
retained in the axle tube. (DaimlerChrysler)
shims or by turning an adjusting nut. Tapered (Fiat, General Motors, Deere & Co.) job of the axle is to propel the vehicle. (Deere & Co.)
roller bearings may be packed with grease or
lubricated from the rear axle
330
Rzeppa-type CV joints—allow each wheel to
move inde- pendently of the vehicle body and
of each other.
A typical independently suspended drive
axle arrangement is shown in Figure 16-38.
Although they look different, these axles
transfer power in much the same manner as
solid drive axles.
Figure 16-39 is an example of how an
independently suspended drive axle and
wheel hub are assembled. The hub is firmly
attached to the suspension control arm. The
inner portion of the hub rotates inside of a
bearing and acts as a mounting flange for the
wheel and brake assembly. The stub axle is
splined to the hub and drives it. The
universal joint allows free movement of the
suspension control arm. Some splined axles
can slide to compensate for changes in axle
length when the rear suspension moves up
and down.
arrangement of gears that
Summary
standard and locking.
All rear axle assemblies have the same
basic design and operate by the same
principles. Rear end variations depend on
whether the vehicle has a solid-axle or inde-
pendent rear suspension, a removable or
integral carrier, semi-floating or full-floating
axles, and a standard or limited- slip
differential.
The major parts of the rear axle assembly
are the dif- ferential assembly, rear axle
housing, drive axles, bearings, and seals.
Engine power enters the drive pinion gear
Rear drive axle has been To
through the differential pinion yoke and drive
(central shaft)
shaft assem- bly. The drive pinion gear
turns the ring gear. The
Wheel
bearings
CV joint
Independent
rear suspension
Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 331
Operation
interaction of the ring and pinion assembly Brake
turns the power at a 90angle and reduces its carrier plate
speed. The ring gear is bolt- ed to the
differential case. Power flows from the ring
gear into the differential case, which transfers
Spacer
the power to the spider gears. The spider
tube
gears transfer the power to side gears, which
then transfer the power to the drive axles and Brake disc rear
rear wheels.
Roller
The differential assembly has three
bearing
purposes. It redi- rects the drive shaft rotation Shock absorber
in a 90angle, reduces rotat- ing speed to
increase power, and allows the vehicle to Wheel bearing Dust
make turns without wheel hop or axle cap Oil seal
breakage.
The relative positions of the ring and Gasket ring
Stub axle
drive pinion gears must be set exactly, or the
gears will be noisy and wear out prematurely.
The position of the ring and drive pinion gears
in the case and in relation to each other must
be carefully adjusted.
The differential case assembly allows the
vehicle to make
turns without wheel hop. It has an Rear drive axle
allows the rear wheels to turn at different (central shaft)
speeds. There are two
kinds of differential case assemblies,
Axle oil seal
The standard differential is composed of
meshing spi-
Cardan U-joint
der and side gears, enclosed in a differential
case. The ring gear is bolted to the case.
Power flow is through the case, into the spider Rear wheel
gears, and on to the side gears. The side hub
gears are splined to the drive axles. They
transfer power to the drive axles and rear
wheels.
When driving on slippery surfaces, the rear
wheels of a vehicle with a standard differential
will often slip. This is because the differential Control arm
willDifferential
always drive the wheel with the least Disc shroud left
traction.
overcome
rotated (top view) this problem, various
kinds of locking differentials are used. They
increase traction by sending power to the
wheel with the most traction.
Stub axle
CV joint
Figure 16-39. This shows how a stub axle and universal joint of an independently suspended drive axle are installed to a hub and
wheel of a vehicle with an independent rear suspension. (Porsche)
Stub Figure 16-38. The drive axle of a vehicle with an independent
CV joint axle Differential rear suspension consists of three shafts and two U-joints. The
central shaft is connected through the U-joints to a short
shaft, or stub axle, on either side. Stub axles are splined to the
wheel hub and side gears. Note that the differential has been
330 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and
rotated 90for the purpose of illustration. Operation
The most common locking differential is
the limited- slip differential. One type uses
clutch packs placed between the side gears
and the differential case. Friction discs are
splined to the side gears; steel plates are
dogged to the case. The clutch packs are
pressed together by the pressure of the spider
gears on the side gears.
When the vehicle is moving straight ahead,
the limited- slip differential operates like a
standard differential. The rear axle parts turn
at the same speed, and the clutch packs are
not used. When a wheel starts slipping, the
difference in pressure on the side gears causes
the clutches to apply. The difference in
traction between the inner and outer wheels
is not a factor during normal turns, and the
friction discs and steel plates slip over each
other.
Another version of the limited-slip
differential uses cones instead of clutch
packs. Operation is similar to the clutch-plate
differential.
331
The ratchet differential has a series of
internal cams and ramps that direct power to
the wheel with the most traction. Its operation
depends on relative wheel speeds, rather than
wheel traction. The ratchet differential
transfers power through a set of teeth, which
can be engaged and disengaged. The Torsen
differential uses an arrangement of worms
(drive gears) and worm wheels (driven gears)
to transfer power. On turns or when one
wheel is slipping, the axle gear and worm
wheel arrangement transfers power from
the faster wheel to the slower wheel.
The rear axle housing encloses and
supports the other parts of the rear axle
assembly and forms a reservoir for the rear
end lubricant. The rear brake assemblies are
usually attached to the rear axle housing. The
rear axle housing is attached to the vehicle
body by the suspension system.
Two kinds of rear axle housings are used
on vehicles without independent rear
suspensions. The removable carrier type has
all of its moving parts, except the axles, in a
carrier
332 Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 333
Operation
Each of the following is a locking
that can be unbolted from the rear axle housing. 8. The convex side of ring gear teeth is the side, and 5. Each of the following is used to set the 9. differential except:
The
sheetintegral
carrier type is
metal a one-piece
inspection unit.
cover, It is serviced
located at the by 9. the
Theconcave
standardside of ring gear
differential teeth is the
is composed side. pinion
preload bearing
except:
(A) a solid (A) Torsen differentials.
rear of the housing. of meshing spacer. (B) ratchet differentials.
A modified rear axle housing is used on vehicles and gears enclosed in a (B) a crush (C) limited-slip differentials.
differential case. washer.
having independent rear suspension. The 4. How can rear axle ratio be determined? (A) multiplying engine power.
internal construc- 10. In terms of their construction, what is
tion of the housing is identical to those used 5. If the drive pinion gear has 10 teeth and the major difference between a (B) allowing the vehicle to make turns.
on live axles. (A version of this housing is the ring gear has 35 teeth, what is the rear standard differential and a limited- slip (C) supporting and aligning the drive axles.
used on some front-wheel drive vehicles that axle ratio? differential?
(D) redirecting power flow to the rear
have the engine mounted longitudinally.) 6. Describe the construction of a drive pinion 11. The Torsen differential is a locking wheels.
The rear drive axles transfer power from gear. differential that uses a .
the side gears to the rear wheels. Drive axles 4. Rear axle ratio can be found by dividing the
7. Which of the following parts is used to (A) multiple-disc clutch number of teeth on the ring gear by the
can be solid or independ- ently suspended.
Solid axles are splined with, and supported by, set pinion bearing preload? (B) cone clutch number of teeth on the .
the side gears at the inboard end. The (A) Jam nut. (C) dog clutch (A) side gear
outboard end is supported by axle bearings. (B) Crush washer. (B) spider gear
(D) worm gearset
The axle bearing can be installed on the shaft
or in the housing. Bearings that are installed (C) Lock washer. 12. Explain the function of the rear axle (C) drive pinion gear
on the shaft are usually packed with grease. (D) Castle nut. housing. (D) axle end gear
Bearings that are installed in the housing are
lubricated by rear end lubricant. Seals are
13. Describe the two major kinds of carriers.
used to keep lubricant from leaking out of the 14. In the -floating axle, the weight of the
rear axle housing. vehicle passes through the axle bearing
Solid axles can be semi-floating or full- to the drive axle and on to the wheel
floating. In the semi-floating axle, the weight and tire.
of the vehicle goes through the axle bearing 15. In a(n) -floating axle, the wheel does
to the shaft and out to the wheel. In the full- not carry any of the vehicle weight.
floating axle, the axle drives the wheel but
does not carry any of the vehicle weight. Most
passenger cars have semi-floating axles.
Independently suspended drive axles
resemble drive shaft assemblies. They ASE-Type Questions—Chapter
consist of a central shaft with flexi- ble joints
and stub axles on each end. The flexible
16
joints can be conventional U-joints or CV
joints. They allow each wheel to move 1. Technician A says that every rear axle
independently of the vehicle body and of assembly has a housing, a differential
each other. assembly, and rear drive axles.
Technician B says that every rear axle
housing has axle tubes. Who is right?
(A) A only.
Review Questions—Chapter 16 (B) B only.
(C) Both A and B.
Please do not write in this text. Place your (D) Neither A nor B.
answers on a separate sheet of paper.
2. The most common rear axle assembly
1. Which of the following items does not failures are
belong with the others? .
(A) Rear axle assembly. (A) axle bearing failures
(B) Final drive. (B) pinion yokes failures
(C) Differential. (C) cracked spider gears
(D) Rear end. (D) stripped ring and pinion gears
2. What is independent rear suspension? 3. Each of the following is a primary
3. Which rear end components change the function of the differential assembly
direction of power flow by 90? except:
332
(C) a collapsible spacer.
(D) the rear pinion bearing.
6. The ring gear transfers power directly from
the drive pinion gear to the . (A) determining the depth of the drive
(A) axle flange
(B) differential case
(C) differential carrier
(D) differential pinion yoke
7. A rear-wheel drive vehicle cannot be driven
because one of its drive wheels is parked
on ice. Technician A says that the ring gear
and differential case will drive the spider
gears. Technician B says that the differential
spider gears will walk around the side gear
related to the wheel on dry pavement. Who
is right?
(A) A only.
(B) B only.
(C) Both A and B.
(D) Neither A nor B.
8. Locking differentials overcome traction
problems by sending power to . (A) conventional versus constant-velocity
(A) the wheel with traction
(B) both wheels
(C) the slipping wheel
(D) the wheel bearings
Manual Drive Trains and Axles Chapter 16 Rear Axle Assembly Construction and 333
Operation
(D) MacPherson differentials.
10. Each of the following functions is served
by the rear axle housing except:
pinion gear in the carrier.
(B) forming a reservoir for rear end
lubricant.
(C) accommodating suspension system
attachment.
(D) supporting stationary parts of rear
brake assemblies.
11. Each of the following types of drive axles
is found on rear-wheel drive vehicles
except:
(A) full-floating axles.
(B) Rzeppa axles.
(C) semi-floating axles.
(D) independently suspended axles.
12. Major differences among rear-wheel drive
vehicles with solid-axle rear suspension
include each of the following except:
U-joints.
(B) removable versus integral carrier.
(C) semi-floating versus full-floating
axles.
(D) standard versus limited-slip
differential.