MECHANICAL ENGINEERING

DEPARTMENT

LAB REPORT
(TITLE: PERFORM REAR WHEEL DRIVE
DIFFERENTIAL UNIT SERVICE)

COURSE CODE : DJA3022

COURSE NAME : AUTOMOTIVE WORKSHOP PRACTICE 2 (CHASSIS)
PROGRAMME / CLASS : DAD / DAD3B
LECTURER : EN ARIFF FARHAN BIN IBRAHIM

NO. MATRIX NUMBER NAME

1 15DAD18F2016 MUHAMMAD AIMAN BIN MOHAMMAD KAMAL

2 15DAD18F2005 MOHAMAD HAZWAN BIN AZIZ

3 15DAD18F2001 AHMAD SHAUQY BIN ABDUL AZIZ

4 15DAD18F2014 IRFAN ANAQI BIN AZRULHISHAM

OBJECTIVE
Upon completion the task, students should be able to:
1. Execute differential unit on road test
2. Conduct overhaul on differential unit
3. Adjust free-play, load and backlash of differential unit
4. Assemble differential unit
5. Replace differential fluid

INTRODUCTION:
Rear wheel axle systems

 An axle is a central shaft for a rotating wheel or gear.

 On wheeled vehicles, the axle may be fixed to the wheels, rotating with them, or fixed
to the vehicle, with the wheels rotating around the axle.
 In the former case, bearings or bushings are provided at the mounting points where
the axle is supported.
 In the latter case, a bearing or bushing sits inside a central hole in the wheel to allow
the wheel or gear to rotate around the axle. 

Differential unit
 The differential is a device that splits the engine torque two ways, allowing each
output to spin at a different speed
 The differential is found on all modern cars and trucks, and also in many all-wheel-
drive (full-time four-wheel-drive) vehicles.
 These all-wheel-drive vehicles need a differential between each set of drive wheels,
and they need one between the front and the back wheels as well, because the front
wheels travel a different distance through a turn than the rear wheels.
TOOL & EQUIPMENTS:

Socket 13mm Spanner 18mm & 19m

Ball-pen hammer
SAFETY PRECAUTIONS:
1. Understand the safety procedures specified by the lecturer.
2. Always aware, any machine or tool used in the practical task.
3. Do yours tasks in an organized manner as this can minimize the risk of accident
occur.
4. Read and follow the experimental method and check with the lecturer if any problem
occur.

PROCEDURE:

1. At first, open up the cover using 13mm socket

2. Open 4 nuts behind the brake plate which connected to the axle.
3. Knock the screw using hammer to pull the shaft out from the axle.

4. Pull the shaft out from the axle slowly without taking off the braking parts.
5. Check the shaft and look if there is any gears are broke.
6. And then check inside the gears inside differential unit to make sure either it is in a
good conditions or not.

7. If there no any problem or broke gears,put the shaft inside the axle back.

8. Tie all of the screw and nuts at its position.

 9. Twist the propeller joint to check either the differential are stuck or could work as
usual.

HOW TO REPLACE DIFFERENTIAL FLUID

Step 1: Get Your Supplies
Before we begin working on draining the differential, it would be wise to
look up in the service manual for the vehicle how much fluid the
differential takes. If the information cannot be found, looking it up online
is the next best thing as long as it is from a reliable source. After finding
the given information needed, go to the nearest store and buy the gasket
for the vehicle and the differential fluid of personal choice. I would
recommend driving the vehicle to the store if at all possible to allow the
fluid to warm up in the axle and flow out much easier when removing the
differential cover. Weather being brand specific or trying to buy the
cheapest fluid possible, it’s all personal preference. Many times true
differential fluid cannot be found, a common replacement is to use
Automatic Transmission Fluid in its place. It would also be a wise idea to
pick up some brake cleaner as well for cleaning the differential cover later
on.

Step 2: Collect Necessary Tools

After buying the fluid now begins the process of gathering the tools
needed for the job. Some of the more common tools needed for this job are
Catch Pan/Bucket

Paper Towels

Ratchet

Breaker Bar

Socket

Pry Bar

Scrapper

Gasket

Funnel

(Helpful but not necessities)

Torque Wrench

Brake cleaner

Ramps

Jack/Jack Stands

An impact driver and impact sockets can also be used if there are some
more expensive tools available, but for the average joe at home, these are
all the tools needed for the job.

Step 3: Draining the Fluid

Depending on the height of the vehicle, it may need to be driven onto
ramps, or jack up the vehicle to have easier access to the different cover.
Once there is access to the cover, begin by placing the catch pan
underneath the differential cover, loosen and remove the bottom bolts on
the cover, and slowly make way up both sides of the cover. Now that there
are only a few bolts remaining, loosen but do not remove them. Now that
they are loosened, gently pry the cover and gasket away from the
differential on the bottom. The differential fluid will the run out the bottom
opening of the differential cover into the catch pan, while the remaining
bolts hold up the cover out of the way.

Step 4: Removing Differential Cover

Remove the few remaining bolts completely and begin to scrape away the
leftover gasket from the differential and covers mounting surfaces.
Continue to clean and scrape away the gasket until both surfaces are few
of anything gasket remnants. Spray brake cleaner along the inside of the
cover over the catch pan to remove any remaining fluid and contaminants.
Dry with a paper towel, preferably with that of a blue shop towel. Spray
one of the towels with brake cleaner and wipe down the surface of the
differential. Once everything has been cleaned, take a dry towel to both the
differential and the cover to dry off both surfaces.

Step 5:
 Step 6: Reinstalling New Gasket and Cover
Apply the new gasket and differential cover back onto the differential.
Hand tighten all bolts, then torque down to the specific specification given
by the vehicle's manufacturer. This may also need to be looked up on the
internet to be found. Not everyone is able to have access to a torque
wrench either, if there is not one to be used, it is not absolutely essential to
use one. As long as all the bolts are tightened down tight using the ratchet
with no leaks it will be good to go.

Step 7: Refilling DIfferential

Once the cover is torqued or tightened down, remove the plug on the
differential housing, using the right sized ratchet. Depending on the type of
vehicle being worked on, the plug could require a 1/4in, 3/8in, or 1/2in.
Ratchet. Once the plug is removed, insert the funnel into the hole, and
begin to pour in the new differential fluid. In many cases, the amount
given by the manufacturer fills almost to where the plug is located on the
housing. However, just to be sure of the amount, only add the amount
given. Once the correct amount of fluid has been added, hand tighten the
plug, then tighten down with a wrench. In some cases, a torque
specification is not given for this plug, tighten down the plug till it is tight,
snug, and not going anywhere, but be very certain not to over tighten or
strip the threads.

Step 8:

Step 9: Test Drive and Check for Leaks

After finishing up the differential all that’s left is to hop in the vehicle,
drive it off the ramps or lower it off the jack stands, and take it out for a
test drive. This will ensure the fluid is lubricating properly and that there
are no leaks. After driving around for a few minutes to warm up the fluid,
return to your home or shop. Inspect the differential and plug for any
leaks, as long as it is dry, and no fluid is leaking the job is now finished.

Step 10: Clean Up

All that's left to do is clean and pick up tools, throw away garbage, and
recycle the used fluid to the correct facility. Now the differential fluid is
brand new and good to go for another 150,000 miles. Although it is not a
common practice done on vehicles daily, it is a good practice to do every
150,000 miles or so to keep the life of the axles and gears making up the
differential in good working order for years to come.
DISCUSSION
1) The function of differential unit
- As part of the front and/or rear axle assembly, the differential plays an integral role in how your car
makes turns. The differential is designed to drive a pair of wheels while allowing them to rotate at
different speeds. This function provides proportional RPMs between the left and right wheels.

2) The operation of differential unit

- When a car turns a corner, one wheel is on the "inside" of a turning arc, and the
other wheel is on the "outside." Consequently, the outside wheel has to turn faster
than the inside one in order to cover the greater distance in the same amount of
time. Thus, because the two wheels are not driven with the same speed, a
differential is necessary. A car differential is placed halfway between the driving
wheels, on either the front, rear, or both axes (depending on whether it’s a front-,
rear-, or 4-wheel-drive car). In rear-wheel drive cars, the differential converts
rotational motion of the transmission shaft which lies parallel to the car’s motion to
rotational motion of the half-shafts (on the ends of which are the wheels), which lie
perpendicular to the car’s motion.
- Assuming the wheels do no slip and spin out of control, the following two
examples of car motion describe how the differential works when the car is going
forward and when it is turning. (see Limited Slip Differential section for wheel
slipping).
- When the car is traveling straight, both wheels travel at the same speed. Thus, the
free-wheeling planet pinions do not spin at all. Instead, as the transmission shaft
turns the crown wheel, the rotary motion is translated directly to the half-shafts,
and both wheels spin with the angular velocity of the crown wheel (they have the
same speed).
- When the car is turning, the wheels must move at different speeds. In this
situation, the planet pinions spin with respect to the crown wheel as they turn
around the sun gears. This allows the speed of the crown gear to be delivered
unevenly to the two wheels.
 3) What is limited slip differential?
- A limited-slip differential (LSD) is a type of differential that allows its two output shafts to
rotate at different speeds but limits the maximum difference between the two shafts.
In an automobile, such limited-slip differentials are sometimes used in place of a standard
differential, where they convey certain dynamic advantages, at the expense of greater
complexity.

4) The operation of limited slip differential unit

- Clutch pack
- As the tabs on the plates are slotted into grooves in the differential case, they turn along
with the case. The clutch plates and discs together are referred to as the clutch pack. The side
gear and axle shaft are separate components and there is a small allowance for movement
between the two.
- Cone clutch
- A cone clutch serves the same purpose as a disk or plate clutch. However, instead of mating
two spinning disks, the cone clutch uses two conical surfaces to transmit torque by friction. ...
They can be used at high engagement speeds and give relatively smooth engagement due to
the gradual increase in transmitted torque.
- Torsen
- Distribute torque between the tires – biasing more torque toward wherever it's best used –
without requiring a loss of traction to operate. They work by managing the friction which
results when torque is applied to the helical gearing.
CONCLUSION
-The conclusion is ,we know how to conduct overhaul on differential unit, how to assemble
differential unit and how to replace differential fluid. After we doing all of this follow the
procedures, we know that how to doing correctly and properly. We also get new information
from this hands on such as how it operate and it function.

REFERENCE
- https://web.mit.edu/2.972/www/reports/differential/differential.html
- https://en.wikipedia.org/wiki/Limited-slip_differential
- https://www.sunautoservice.com/what-is-a-differential-on-a-car/
- https://www.houstonrebuiltaxles.com/how-differentials-work-locking-differentials-clutch
-https://www.quora.com/How-does-a-cone-clutch-work
- https://torsen.com/how-it-works/