DIFFERENTIAL

Function:

The differential is very much essential when the vehicle is taking a turn. On a turn the
front wheels are rotated with the help of steering. As is clear from the fig. The outer rear wheel
has to travel say a distance A which is more than the distance B traveled by the inner wheel. If
both the rear wheels are rotating at same speed then the outer wheel will be skidding. The
skidding involves sliding friction and is very harmful for the life of the types. For avoiding this
skidding the differential mechanism allows the outer wheel to revolve at a higher speed than the
inner wheel while turning a corner.

Construction and Working

The differential mechanism as shown in fig. Consists of the following components.

1. Crown wheel or Ring gear.
2. Differential cage.
3. Sun gears.
4. Planet pinions.
The drive pinion meshes with the crown wheel. The crown wheel is free to rotate on the
rear axle half shaft. The sun gears are keyed on the ends of each half shaft. The cage is rigidly
attached to the crown wheel. The cage consists of a pin, on which two planet pinions are mounted.
These planet pinions are free to rotate on the pin. The planet pinions mesh with the sun gears.
 When the vehicle is going straight, the flow of power from the drive pinion is as shown in
fig. The drive or bevel pinion gives power to the crown wheel. The crown wheel, cage, the pin
and the planet pinions are rotating as single unit. The planet pinions are not revolving on the pin
as their axes and these planet pinion teeth are transmitting the power to sun gears. The sun gears
and the half shafts are keyed together and revolve due to the rotary motion of the planet gears as a
whole.
When the car is negotiating a curve, the planet gear rotates on its shaft to permit the outer
rear wheel to turn more quickly than the inner rear wheels.

Rear Axles

The propeller shaft gives power to the differential. The differential turns the flow of power
at rt. < and the sun gear shafts transmit the power to the wheel. Axle housing is either of single
piece or of split type. Housing completely encloses the shaft, the gears, bearings lubricating
arrangements and protect these parts from moisture dust, etc. The sun gear shaft, which are
transmitting the power are called, live axles”.

Types of rear axles:

1. Fully Floating Axle.

2. Semi Floating Axle.
3. Three quarter Floating Axle.

1. Fully Floating Axle

A fully floating axle is shown in fig. This type of axle transmits only the driving torque.
The weight of the vehicle and the end thrusts are not carried by the axles. Due to the reason that
axle is not subjected to any strains due to the weight of the vehicle and its only function is to
transmit a rotary motion, the name given to it is fully floating axle. The wheel hub C is supported
by two bearings A and B running directly upon the axle housing. The axle shaft D is fastened to
the wheel hub flange e by means of the coupling F. The bearings are kept in position by retainer
and lock nuts.
 This type of axle is very strong and is used for heavy duty vehicles. If an axle shaft breaks,
there would be no danger of the wheel coming off and the shaft can be removed and replaced
easily. But this is the costliest type of drive.

2. Semi Floating Axle

A semi floating axle is shown in fig. In this type of axle, whole of the load of the rear
portion of the vehicle and the end thrust is carried by the axle and the driving torque also. The
vehicle load is transmitted to each of the half shafts through axle casing and the bearings.
The wheel hub is rigidly fixed to the outer end of the axle shaft. The outer race of the
bearing fits into the axle sleeve and the inner race fits of the axle shaft. The bearing is held in its
position by the rearing retainer plate and the retainer. For replacement of the axle shaft, the
vehicle is jacked up. The wheel, the drum and the bearing retainer plate must be removed in order
to remove the axle shaft.
3. Three Quarter floating Axle

A three quarter floating axle is shown in fig. This design is a compromise between the
fully floating axle and the semi-floating type. The bearing is carried on the axle casing. The hub is
rigidly fixed to the outer end of the axle shaft. The axle shaft is not supporting any weight but will
have to withstand the end thrusts besides transmitting the driving torque.
Due to the reason that three quarter floating axle has only one bearing at the outer end, but
even then it takes some bending stresses, it, therefore, does not resemble the fully floating type.

Rear Axle Systems of Indian Vehicles

S No. Vehicle makes Type

1. Fait Semi Floating
2. Jeep Semi Floating
3. Hindustan Three quarter floating
Ambassador Mark - II
4. Dodge Fully floating
5. Ashok-Leyland Fully floating

Types of rear axle drives:

Various arrangements are employed to take the torque reaction and driving thrust of the
axle casing. The main systems are
1. The Hotchkiss open type drive
2. The torque tube drive
3. The de-Dion drive
1. Hotchkiss drive:

Fig shows Hotchkiss drive. It consists of propeller shaft, two universal joints and a slip
joint. The propeller shaft is not enclosed in a tube. The spring is fixed rigidly in the middle of the
rear axle. The front end of the spring is rigidly fixed on the frame. The rear end is supported on a
shackle.
The rear-end torque is absorbed by the rear end springs. When the car is moving forward,
the rear end torque causes the front halves of the springs to be compressed as the rear halves of the
springs are expanded.

When the springs deflect, the pinion shaft also changes its position. If there is only one
universal joint at the front end of the propeller shat, it will bend under this condition. Therefore
another universal joint at the rear end of the propeller is necessary. The slip joint compensates for
difference in length of the propeller shaft. This drive is used now-a-days in most of the cars. The
torque reaction, weight of the body, the driving thrust and side thrust are taken by the springs.

2. Torque-tube drive:

The propeller shaft is enclosed in a hollow tube. The tube is rigidly bolted to the
differential housing at one end. The other end of the tube is fastened to the transmission through a
flexible joint. A bearing are fitted with the tube and supports the propeller shaft. Only one
universal joint is placed between the transmission and the propeller shaft. Sliding joint is not
needed.
 On many cars, a pair of truss rods is attached between the rear-axle housing and the
transmission end of the torque tube. The rear-end torque is absorbed by these members (truss rods
and torque tube). The springs take only the side thrust in torque tube drive. Also it supports the
weight of the body.

Transfer box or Transfer case:

A transfer case is a part of a four-wheel-drive system found in four-wheel-drive and all-

wheel-drive vehicles. The transfer case is connected to the transmission and also to the front and
rear axles by means of drive shafts. It is also referred to as a "transfer gear case", "transfer
gearbox”, “transfer box" or "jockey box" (Australia).

Functions

The transfer case receives power from the transmission and sends it to both the front and
rear axles. This can be done with a set of gears, but the majority of transfer cases manufactured
today is chain driven. On some vehicles, such as four-wheel-drive trucks or vehicles intended for
off-road use, this feature is controlled by the driver. The driver can put the transfer case into either
"two-wheel-drive" or "four-wheel-drive" mode. This is sometimes accomplished by means of a
shifter, similar to that in a manual transmission. On some vehicles this may be electronically
operated by a switch instead. Some vehicles, such as all-wheel-drive sports cars, have transfer
cases that are not selectable. Such a transfer case is permanently "locked" into all-wheel-drive
mode.
 An on-road, transfer case synchronizes the difference between the rotation of the front and
rear wheels, in much the same way the differential acts on a given axle. This is necessary, because
the front and rear tires never turn at the same speed when front and rear tire sizes differ.
Transfer cases designed for off-road use can mechanically lock the front and rear axles
when needed (e.g. when one of the axles is on slippery surfaces or stuck in mud, whereas the
other has better traction). This is the equivalent to the differential lock.
The transfer case may contain one or more sets of low range gears (generally for off-road
vehicles). Low range gears are engaged with a shifter or electronic switch. On many transfer
cases, this shifter is the same as the one that selects 2WD or 4WD operation. Low range gears
slow down the vehicle and increase the torque available at the axles. Low-range gears are used
during slow-speed or extreme off road maneuvers, such as rock crawling, or when pulling a heavy
load. This feature is often absent on all-wheel-drive cars. Some very large vehicles, such as heavy
equipment or military trucks, have more than one low-range gear.

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