Intermediate Technicians Course

FINAL GEAR &

DIFFERENTIAL GEAR

3-6 FINAL GEAR &

DIFFERENTIAL GEAR
TAPER ROLLER BEARING
THRUST WASHER
DIFFRENTIAL CASE
ADJUSTING NUT
THRUST WASHER
DIFFERANTIAL PIGNON
DIFFERANTIAL
SIDE GEAR

SHIM
BEARING CAGE

TAPER ROLLER BEARING

BEARING CAP

SPIDER

OIL SEAL

FLANGE YOKE
DIFFRENTIAL CASE

RING GEAR
DIFFRENTIAL CARRIER CASE
CYLINDRICAL ROLLER BEARING
RETAINER RING

DRIVE PIGNON

FINAL GEAR TYPES

SPIRAL BEVEL GEAR

HYPOID GEAR

DIFFERENTIAL GEAR

RING GEAR

DIFFERENTIAL PINION & SHAFT

DIFFERENTIAL CASE

SIDE GEAR & AXLE SHAFT

DIFFERENTIAL GEAR

WHEN MOVING STRAIGHT AHEAD

SPIDER
DIFFERENTIAL GEAR OPERATION

WHEN TURN &

SPIDER
DIFFERENTIAL GEAR OPERATION

INTER AXLE DIFFERENTIAL PIGNON

INTER AXLE DIFFERENTIAL GEAR

INPUT SHAFT
SHIM

ADJUST NUT
SHIM

THROUGH SHAFT

SHIFTER SLEEVE
DRIVE GEAR
HYPOID PIGNON
PIGNON DRIVE GEAR
SPIDER

AXLE HOUSING
SHIM

CYLINDRICAL
ROLLER BEARING
DIFFERENTIAL CARRER

INTERAXLE DIFFERENTIAL

SLEEVE

DRIVE GEAR INTER AXLE DIFF

THROUGH SHAFT

INPUT

REAR/REAR AXLE
REAR/FRONT AXLE

FUSE BOX
COMPRESSED AIR FROM TANK
INTER AXLE DIFF SWITCH
PISTON

AIR
EXHAUST

SHIFT FORK

ON
(PUSH)
INDICATOR LAMP

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)
PIGNON HEIGHT
ADJUSTING VALUE

SET NO.

SET NO.

PARTS NO.

FINAL GEAR SET

(2)THE CONICAL DISTANCE FOR ADJUSTING

THE DRIVE PINION END FOR OPTIMUM TOOTH
CONTACT DURING ASSEMBLY IS RECORDED.
(REFER TO THE WORK SHOP MANUAL.)
PIGNON DEPTH GAUGE
CONICAL DISTANCE

ADJUSTING SHIM

CONICAL DISTANCE

(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.

PIGNON DEPTH GAUGE

THE ENGRAVED
VALUE "a "

CONICAL DISTANCE

ADJUSTING SHIM

DRIVE PINION HEIGHT WITH SHIMS

ADJUSTMENT OF PINION HIGHT (CONOCAL DISTANCE)

EXAMPLE:

33mm

0.2 mm

STANDARD
PINION
HIGHT
"A"

THE
ENGRAVED
VALUE
"a"

32.8mm

MEASURING
PART
"A"

TOOTH CONTACT AND ADJUSTING METHOD

SATISFACTORY(NEW)

SATISFACTORY(AFTER BREAKING INPERIOD)

TOE

CONTACT

FLANK
CONTACT

HEEL
CONTACT

FACE
CONTACT

(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.
TAPER ROLLER BEARING
THRUST WASHER
DIFFRENTIAL CASE
ADJUSTING NUT
THRUST WASHER
DIFFERANTIAL PIGNON
DIFFERANTIAL
SIDE GEAR

SHIM
BEARING CAGE

TAPER ROLLER BEARING

BEARING CAP

SPIDER

OIL SEAL
FLANGE YOKE
DIFFRENTIAL CASE

RING GEAR
DIFFRENTIAL CARRIER CASE
CYLINDRICAL ROLLER BEARING
RETAINER RING

DRIVE PIGNON

(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.

(7) What trouble will occur if the differential lock switch

is ON while the vehicle is traveling on paved road?

Tire wear will be promoted.

(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

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.

OUTLINE & STRUCTURE of NO SPIN DIFFERENTIAL

Spider & center cam

Hold-out ring

Driven clutch

spring

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.

NO SPIN DIFFELENTIAL OPERATION

1 STRAIGHT FORWARD

NO SPIN DIFFELENTIAL OPERATION

1 STRAIGHT FORWARD DRIVING
Center cam

Spider

1
Driven clutch

3
Backlush
of the
clutch teeth

2 STRAIGHT FORWERD BREAKING

NO SPIN DIFFERANTIAL OPERATION

3 TURNNING FORWARD(1)

out

In

3 TURNNING FORWARD(2)

Center cam

Spider

Driven clutch
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)

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.

Center cam groove

Hold out ring

E
F

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).

F
Center cam groove

E
Hold out ring projection

3 TURNNING FORWARD(5)

Spring

Center cam teeth

Outside driven clutch

C
The outside driven clutch(C) are moved to original engagement
along the center cam teeth(B) by the spring(C)