Intermediate Technicians Course

FINAL GEAR &

DIFFERENTIAL GEAR
3-6 FINAL GEAR &
DIFFERENTIAL GEAR
FINAL GEAR TYPES
DRIVE PIGNON
CYLINDRICAL ROLLER BEARING
RETAINER RING
DIFFRENTIAL CARRIER CASE
RING GEAR
DIFFRENTIAL CASE
BEARING CAP
THRUST WASHER
DIFFERANTIAL PIGNON
DIFFERANTIAL
SIDE GEAR
THRUST WASHER
SPIDER
DIFFRENTIAL CASE
TAPER ROLLER BEARING
ADJUSTING NUT
SHIM
BEARING CAGE
TAPER ROLLER BEARING
OIL SEAL
FLANGE YOKE
DIFFERENTIAL GEAR
SPIRAL BEVEL GEAR HYPOID GEAR
DIFFERENTIAL GEAR
RING GEAR
DIFFERENTIAL PINION & SHAFT
DIFFERENTIAL CASE
SIDE GEAR & AXLE SHAFT
DIFFERENTIAL GEAR OPERATION
WHEN MOVING STRAIGHT AHEAD
SPIDER
DIFFERENTIAL GEAR OPERATION
WHEN TURN &
SPIDER
INTERAXLE DIFFERENTIAL
INPUT SHAFT
SHIM
SHIFTER SLEEVE
DRIVE GEAR
HYPOID PIGNON
PIGNON DRIVE GEAR
SPIDER
SHIM
DIFFERENTIAL CARRER
CYLINDRICAL
ROLLER BEARING
AXLE HOUSING
THROUGH SHAFT
SHIM
ADJUST NUT
INTER AXLE DIFFERENTIAL PIGNON
INTER AXLE DIFFERENTIAL GEAR
REAR/REAR AXLE
REAR/FRONT AXLE
SLEEVE
DRIVE GEAR
INTER AXLE DIFF
THROUGH SHAFT
INPUT
INTER AXLE DIFF SWITCH
FUSE BOX
COMPRESSED AIR FROM TANK
PISTON
SHIFT FORK
AIR
EXHAUST
INDICATOR LAMP
ON
(PUSH)
DIFFERENTIAL LOCK SWITCH OPERATION
2)SERVICE POINTS: Final gear set
(1)THE DRIVE PINION AND RING GEAR ARE REPLACED
AS A SET. ( SET NO. IS RECORDED)
FINAL GEAR SET
SET NO.
SET NO.
PARTS NO.
PIGNON HEIGHT
ADJUSTING VALUE
(2)THE CONICAL DISTANCE FOR ADJUSTING
THE DRIVE PINION END FOR OPTIMUM TOOTH
CONTACT DURING ASSEMBLY IS RECORDED.
(REFER TO THE WORK SHOP MANUAL.)
CONICAL DISTANCE
ADJUSTING SHIM
CONICAL DISTANCE
PIGNON DEPTH GAUGE
(3)ASSEMBLY MATCH MARKS ARE PROVIDED ON
THE SIDE BEARING CAP AND THE DIFFERENTIAL
GEAR CASE.
SIDE BEARING CAP MATCH MARKS
(4)THE ADJUSTMENT SEQUENCE IS AS FOLLOWS:
The drive pinion bearing preload measurement by
small torque wrench.
If the pre-load is not of specific value, adjust by
shim or spacer.
The ring gear backlash and total pre-load by
turning the adjusting nuts of both side.
(5)THE TOOTH CONTACT IS ADJUSTED
BY ADJUSTING THE DRIVE PINION HEIGHT
WITH SHIMS.
DRIVE PINION HEIGHT WITH SHIMS
THE ENGRAVED
VALUE "a "
ADJUSTING SHIM
CONICAL DISTANCE
PIGNON DEPTH GAUGE
ADJUSTMENT OF PINION HIGHT (CONOCAL DISTANCE)
EXAMPLE:
33mm 0.2 mm = 32.8mm
STANDARD
PINION
HIGHT
" A "
THE
ENGRAVED
VALUE
" a "
MEASURING
PART
" A "
TOOTH CONTACT AND ADJUSTING METHOD
SATISFACTORY(NEW) SATISFACTORY(AFTER BREAKING INPERIOD)
TOE
CONTACT
FLANK
CONTACT
HEEL
CONTACT
FACE
CONTACT
DRIVE PIGNON
CYLINDRICAL ROLLER BEARING
RETAINER RING
DIFFRENTIAL CARRIER CASE
RING GEAR
DIFFRENTIAL CASE
BEARING CAP
THRUST WASHER
DIFFERANTIAL PIGNON
DIFFERANTIAL
SIDE GEAR
THRUST WASHER
SPIDER
DIFFRENTIAL CASE
TAPER ROLLER BEARING
ADJUSTING NUT
SHIM
BEARING CAGE
TAPER ROLLER BEARING
OIL SEAL
FLANGE YOKE
(6)ON VEHICLES THAT OFTEN TRAVEL ON MOUNTAIN
ROADS OR MUDDY ROADS, THE DIFFERENTIAL
CASE AND PINION ARE SUSCEPTIBLE TO WEAR,
SO THEY MUST BE CHECKED.
(1) Why can the left and right side bearing caps not be
replaced?
Since they are integrated with gear case, the threads
will not match when they are replaced.
(2) Why are gears provided with backlash ?
Escape clearance during expansion; if not provided,
seizing, noise, and groaning noise will result.
(3) Why is bearing preload provided?
To extend bearing life.
(4) Why is the drive pinion height adjusted?
To optimize tooth contact.
(5) Why are the drive pinion and ring gear replaced
as a set?
For integrated lapping.
(6) What will happen if the drive pinion and ring gear
tooth contact is insufficient?
Noise, groaning, tooth loss, pitching.
Tire wear will be promoted.
(7) What trouble will occur if the differential lock switch
is ON while the vehicle is traveling on paved road?
(8) What trouble will occur if the differential lock switch
is OFF while the vehicle is traveling on muddy road?
Slipping; Can not escape slippy condition; interaxle
differential seizing.
(9) What might cause the drive pinion to pitch?
Overloading, faulty adjustment, faulty oil, faulty
machining, faulty hardening.
(10) What will be happen if API standard GL-4oil is used
for the hypoid gear?
Tooth face pitching will be promoted.
Intermediate Technicians Course
NO SPIN
DIFFERENTIAL
NO SPIN DIFFERENTIALS
L R
FUNCTION of NO SPIN DIFFERENTIAL
Wheel at L side loses traction but
dose not spin.
Therefore wheel at R side keeps
traction and the vehicle will be
moved.
Spider & center cam
Hold-out ring
spring
Driven clutch
OUTLINE & STRUCTURE of NO SPIN DIFFERENTIAL
FUNCTION of NO SPIN DIFFERENTIAL
Wheel at L side loses traction but dose not spin.
L
R
Therefore wheel at R side keeps traction
and the vehicle will be moved.
NO SPIN DIFFELENTIAL OPERATION
F
F
1 STRAIGHT FORWARD
NO SPIN DIFFELENTIAL OPERATION
1 STRAIGHT FORWARD DRIVING
2
3 1
Spider
Center cam
Driven clutch
Backlush
of the
clutch teeth
2 STRAIGHT FORWERD BREAKING
B
2
1 3
NO SPIN DIFFERANTIAL OPERATION
F
F
out
In
3 TURNNING FORWARD(1)
A
C
B
Driven clutch
Center cam
Spider
3 TURNNING FORWARD(2)
The out side driven clutch C) start to be rotated
faster than spider A) and clutch teeth slide on
the center cam teeth B) to disengage.
2 TURNNING FORWARD (3)
A
C
E
F
Center cam groove Hold out ring
The outside driven clutch(C) is disengaged with the Spider(A)
and hold out ring(E) is out of the Center cam groove(F) to hold
engagement.
3 TURNNING FORWARD (4)
At end of turning, the outside driven clutch(A) decrease the rotating speed
than the hold out ring projection(E). Aligned with center cam groove(F).
E
F
C
Center cam groove
Hold out ring projection
3 TURNNING FORWARD(5)
B
C
G
Spring
Center cam teeth
Outside driven clutch
The outside driven clutch(C) are moved to original engagement
along the center cam teeth(B) by the spring(C)