Driveline Operation

Chapter 75

© 2012 Delmar, Cengage Learning

 Objectives
• Describe the operation of universal joints
• Explain how a differential works
• Understand the differences between types of
limited slip differentials
• Describe the different types of rear axles and
bearings
• Select the correct gear oil for different
applications

© 2012 Delmar, Cengage Learning

 Objectives (cont’d.)
• Identify differences between four-wheel-drive
types
• Explain the parts and operation of a transfer case

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 Introduction
• Driveline
– Parts that transfer power from transmission to
rear wheels
• Driveshaft and universal joints
• Axles and axle bearings
• Differential
• Live axles
– Turn with the wheels
• FWD vehicles
– Have a transaxle with two halfshafts
© 2012 Delmar, Cengage Learning
 Drive Shaft (RWD)
• Typically include two universal joints and slip yoke

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 Slip Yoke
• Attached to universal joint on front end of drive
shaft
– Other end fits over splines on output shaft
• Slides in and out of transmission
– As distance between transmission and
differential changes
• Automatic transmission
– Sometimes a seal goes over the output shaft
• Keeps ATF from leaking out of slip yoke through
its vent hole

© 2012 Delmar, Cengage Learning

 Universal Joints
• U-joints are located at ends of drive shaft
– Axle moves up or down: U-joint allows changes
in angle at ends of drive shaft
• Cross and yoke
– Most popular design
• Usually pressed fit into the yokes on drive shaft
– Snap rings fit into grooves in the yoke
• Popular method of connecting to the differential
– U-bolts hold U-joint centered between tabs in the
rear flange
© 2012 Delmar, Cengage Learning
 Two-Piece Driveshaft
• During factory balancing
– Weights spot-welded to drive shaft
– Vehicles with longer wheel base have a two-
piece drive shaft
• Correctly assembled driveshaft
– U-joint cups in alignment
• Improperly assembled: severely out of balance
• Center support bearing
– Holds center of shaft where two shafts attach
– Sealed bearing is supported in rubber mount
© 2012 Delmar, Cengage Learning
 Driveshaft Angle
• Cardan U-joint operated at an angle
– Speed of driven shaft varies as it revolves
– Angle is increased: change in velocity increases
• Most manufacturers use angles less than three
to four degrees with single U-joints
• One-piece drive shaft
– U-joints arranged so they cancel each other
• Angles at each end of drive shaft
– Must be almost equal or vibration results

© 2012 Delmar, Cengage Learning

 Constant Velocity Joints
• Vibration caused by drive shaft speed
– Canceled by putting two Cardan U-joints next to
each other
• U-joints: connected by centering socket and yoke
– Phased to cancel each other’s angle
– Speed change never leaves the joint
• CV joints: used on larger luxury vehicles and
pickup trucks
• Ball and trunnion: used on FWD vehicles

© 2012 Delmar, Cengage Learning

 Differential and Differential
Construction
• Differential transfers power to wheels
– Increases torque with final drive gear reduction
• Differential construction
– Parts are housed in axle housing
– Pinion gear is splined to flange
• Crush sleeve functions
– Keeps bearing separate from races
– Maintains preload on bearings
– Keeps front bearing race from spinning

© 2012 Delmar, Cengage Learning

 Differential Housing
• Differential housing holds drive pinion and case
– Banjo housing has removable pumpkin
– Salisbury axle (integral): third member not
removable
• Top of housing has vent and breather tube
– Breather tube usually runs into fender well
– Vent may have one-way check valve

© 2012 Delmar, Cengage Learning

 Differential Operation
• Each axle has splines
– Mesh with side gear splines
• Differential pinions mesh with side gears
– Mounted on pinion shaft
• Spider gears
– Side gears and differential pinions
• Power flow
– During corner: side gears rotate against
differential pinions

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 Differential Gears
• Hypoid gearset
– Pinion gear: lower than the centerline of ring gear
– Teeth of hypoid gear: curved in spiral shape
– Each tooth has concave and convex side
• Convex side is the drive side
• Concave side is the coast side

© 2012 Delmar, Cengage Learning

© 2012 Delmar, Cengage Learning
 Gearsets
• Ring and pinion gears: produced as matched set
– Ring and pinion gears marked
• Assembled with marks facing each other
– Must be mounted together in exact position
• Gearset types
– Hunting gearset: pinion gear tooth moves around
until it contacts all of the ring gear teeth
– Non-hunting gearset: one tooth on pinion gear
meshes with same tooth on ring gear
– Partial non-hunting gearset: one pinion tooth
contacts two to three different ring gear teeth
© 2012 Delmar, Cengage Learning
 Axle Ratio and Limited Slip
Differential
• Axel ratio: divide number of teeth on pinion gear
into number of teeth on ring gear
– Manual transmission has lower ratio
– Higher ratio produces better fuel economy
• Limited slip differential: locks up spider gears
when one wheel loses traction
– Puts traction on the still wheel
– Spider gears not locked during normal operation

© 2012 Delmar, Cengage Learning

 Types of Limited Slip
Differentials
• Several designs
– Most popular has clutch packs
• Torque applied to clutch pack: side gear locks
– Older units: four pinion gears and two pinion shafts
– Cone-type: cones forced against case by springs
– Viscous coupling: sealed unit contains silicone
fluid
– Detroit Locker differential: has a ratcheting pair of
clutch packs that force it to lock up

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 Drive Axles and Bearings and
Semi-Floating Axel Bearing Types
• Drive axles
– Support weight of the car
• Semi-floating axle bearings
– Bearing retained axle: bearing with inner race
pressed onto axle shaft
• Retainer ring pressed onto axle shaft after bearing
• Outside of bearing fits tightly into axle housing
– C-lock axle: bearing rides on hardened axel areas
• Outer bearing race and rollers fit into axle housing
• Axle bearing lubricated by oil mist
© 2012 Delmar, Cengage Learning
 Independent Rear Suspension
Axles
• Vehicle has independent rear suspension
– Axles must pivot independently
• Two swing axles
• Each axle has universal joint at one or both ends
• Similar to those used in front-wheel-drive cars

© 2012 Delmar, Cengage Learning

 Gear Oils
• Special heavy liquid lubricant for gears and
bearings
– Prevents high temperatures and scoring of parts
• Additives prevent corrosion and oxidation,
reduce friction, limit wear, and prevent foaming
– EP additives: cause formation of compounds
• API system
– Classifies gear lubricants
• Limited slip gear oils
– Require friction modifier additive
© 2012 Delmar, Cengage Learning
 Four-Wheel Drive and Four-
Wheel Drive Axle Assembly
• Types of four-wheel-drives
– Operates like RWD with extra differential in front
– Operates like FWD with extra differential in rear
– All-wheel-drive are always in four-wheel-drive
• Axle assembly for four-wheel-drive: similar to
two-wheel-drive rear axle
– Drive shaft and universal joints transfer by way of
transfer case
– Ends of axle housing on front axles have to pivot
to allow front wheels to be turned
© 2012 Delmar, Cengage Learning
 Transfer Case
• Allows for shifting between low and high range
and two-wheel and four-wheel drive
• Power flow using gear drive transfer case
– 2H: through locked planetary gearset to
mainshaft and rear differential
– 4H: input shaft to locked planetary gearset
– 4L: shifter moves clutch rearward
• Planetary low range
– Planetary transfer case: ring gear pressed into
housing so it is held stationary
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 Locking Hubs
• Allow four-wheel drive to be used in two-wheel
drive
• Types
– Manual locking hubs: have on and off locks on
front spindles
• Unlocked: front wheels not driven
– Automatic locking hubs: come on when vehicle
shifted into four-wheel drive

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 All-Wheel Drive
• Characteristics
– All four wheels driven
– Used to improve traction on icy or snowy driving
– Transfer engine power to wheel with most
traction
– Lockout must be included when there is a center
differential
– Viscous coupling allows front and rear wheels to
revolve at different speeds
– Intelligent AWD flexibly distributes torque to
wheels
© 2012 Delmar, Cengage Learning