Assembling and disassembling of differential and rear axle.

Study, 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:

1. A vehicle's wheels rotate at different speeds, mainly when turning corners.

2. The differential is designed to drive a pair of wheels while allowing them to
rotate at different speeds.
3. 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.
4. 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.
5. In automobiles and other wheeled vehicles, a differential is the usual way to allow
the driving road wheels to rotate at different speeds.
6. 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.
7. The engine is connected to the shaft rotating at an angular velocity. .
8. The driving wheels are connected to the other two shafts, and they are equal.
9. 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 can not
change.
10. 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.)

Study:
Differential:
1. 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.
2. The gears or other components make the three shafts rotate.
3. It may seem illogical that the speed of one input shaft can determine the speeds
of two output shafts, which are allowed to vary.
4. Logically, the number of inputs should be at least as great as the number of
outputs.
5. However, the system has another constraint.
6. 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.
7. Thus the system does not have one input and two independent outputs.
8. It has two inputs and two outputs.
1 - Differential housing with riveted gear for final drive
2 - Output shaft/drive flange
3 - Tapered roller bearing inner race
4 - Tapered roller bearing outer race
5 - Bearing body for tapered roller bearing
6 - O-ring
7 - O-ring
8 - Adjusting ring for tapered roller bearing
9 - Output shaft/drive flange
10 - Tapered roller bearing outer race
11 - Tapered roller bearing inner race
12 - Speedometer drive bushing
13 - Speedometer drive gear
14.One-piece thrust washer
15 - Small bevel gears
16 - Large bevel gears
17 – Circlip
 Principle:

1. Input torque is applied to the ring gear (blue), which turns the entire carrier
(blue).
2. The carrier is connected to both sun gears (red and yellow) only through the planet
gear (green).
3. Torque is transmitted to the sun gears through the planet gear.
4. The planet gear revolves around the axis of the carrier, driving the sun gears.
5. 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.

6. If the left sun gear (red) encounters resistance, the planet gear (green) spins as well
as revolving, allowing the left sun gear to slow down, with an equal speeding up of
the right sun gear (yellow).
Requirement :

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

2. Pulling off Tapered roller bearing inner race
3. Remove Tapered roller bearing outer race
4. Remove Bearing body for tapered roller bearing
5. Remove Differential
6. Remove O-rings
7. Remove Adjusting ring for tapered roller bearing 11
Remove Output shaft/drive flange
8. Remove Tapered roller bearing outer race 13 Pulling
off Tapered roller bearing inner race
9. Drive out Speedometer drive gear with drift Fit together with driver bushing Remove
small bevel gears, large bevel gears.
10. 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.
i. 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.