Differential

Prepared By: Aashish Koirala

Introduction
• Differential is a device that splits the engine torque two ways,
allowing each output to spin at a different speed.
• Used in the live axle (i.e. the axle that transmits the power).
Why differential
• Allow drive wheels to turn at
different speeds.
• Speed reduction at pinion ring
gear assembly, resulting in
torque multiplication.
• Turn power flow direction by 90
degrees.
• Avoid slipping of wheels while
accomplishing a turn.
Power flow
• Speed reduction, torque
Tail Pinion
Ring Gear
Differential multiplication.
Gear cage
• Differential cage is mounted on
ring gear and has spider to carry
Bevel bevel pinion gear.
Side gear Spider
pinion gear
• Bevel pinion gear is meshed with
two side gears for rotating it.
• Axle is connected to side gear
Axle Hub Wheel
which rotate hub, thereby
rotating the wheels.
Working principle
• Case 1: Vehicle moving in straight ahead position
• Case 2: Vehicle taking a right turn
• Case 3: Vehicle taking a left turn
Case 1: Vehicle moves in straight ahead
position
• Bevel pinion gear rotates along
with ring gear but does not
rotate in its own axis.
• Bevel pinion gear will push and
make the side gear turn and
both will turn at same speed.
• Spider and bevel pinion gear
assembly will move as a single
solid unit.
Case 2: Vehicle negotiating a right turn
• Differential bevel pinion gear plays a
pivotal role here.
• Thus, bevel pinion gear rotates along
with the ring gear and on its own axis.
• Hence, bevel pinion gear is having
combined rotation.
• Left side gear = sum of rotation and
spinning of bevel pinion gear.
• Right side gear = difference of rotation
and spinning of bevel pinion gear.
Case 3: Vehicle taking left turn
• Bevel pinion gear rotate in
opposite direction than that of
case 2.
• So, left side gear speed =
difference of rotation and spin of
bevel pinion gear.
• Right side gear speed = sum of
rotation and spin of bevel pinion
gear.
Limitation of standard or open differential
• Majority of power is sent to
wheel having low traction.
• So, high traction wheel get less
power.
• This defect could be reduced
using Limited slip differential.
Various adjustments in differential
• Backlash between differential
gears.
• Backlash between Pinion gear and
ring gear.
• Friction movement of tail pinion
taper roller bearing.
• Adjustment of tail pinion depth.
• Thrust pad adjustment.
• Hub bearing axial play adjustment.
Backlash adjustment between differential
gears
Dial gauge
• Set the dial gauge with plunger in
the side gear.
• Hold the differential bevel pinion
gear and rotate the side gear back
and forth. Magnetic stand
• The difference of lowest point and
higher point shown by dial gauge is
the backlash. Plunger

• This backlash can be changed by

selecting the appropriate brass
thrust washer for side gears.
Side gear
Critical factors while adjusting (setting)
differential
• Bearing preload • Gear clearance (Backlash)
• Bearing preload is the process of • Backlash is a gap or a clearance
adding a sustained axial load, between mating gear teeth to let
independent of external load to gear mesh without binding and
a bearing. for providing space for a film of
• Preload too high: bearing lubricating oil between the
overheating and failure. teeth.
• Preload too low: bearing too • Clearance low: binding of teeth,
loose, noise can occur. insufficient space for lubricating
oil.
Problems and troubleshooting in differential
Noisy operation
• Causes • Troubleshooting
• Incorrect backlash of ring gear and • Ensure backlash as specified in the
tail pinion gear. manual with proper preloading of
• Excessive backlash between differential side bearing.
differential gears.
• Adjust backlash with correct thrust
• Broken and pitted gear. washer.
• Knife edging of crown wheel and
• Replace broken and pitted gear
pinion gear teeth.
• Replace crown wheel and pinion,
use correct grade of oil.
Continue…
• Incorrect grade of oil
• Use proper grade and quality of oil
• 85 W 140 /API GL 5
• API = American Petroleum Institute
• GL = ratings
• Higher the oil’s GL ratings, oil can sustain more pressure.
• GL - 5 has lower coefficient of friction due to higher concentration of EP
additives over GL – 4.
• Extreme pressure (EP) additive for heavy duty service.
• Sustain more pressure without any metal to metal contact.
Warranty
• Brand or company
• Timeline
• Scheduled servicing
• Unauthorized modification
• Terms and conditions
Acceptance and rejection of warranty claim

Pitted gear
Causes:
Manufacturing defect (accept)

Broken ring or pinion gear teeth

• Causes:
• Applied too much power with too
much resistance in the tires. (reject)
Thank you!