Differential Assembly: Application and ID
Driveline SystemThe driveline system consists of the following components:
^ Center support bearing
^ Driveshaft assembly
^ Front halfshafts
^ Rear halfshafts
^ Active torque coupling/rear axle
On front-wheel drive (FWD) vehicles, the transaxle transmits power from the engine to the halfshafts.
On 4-wheel drive (4WD) vehicles, power is transmitted from the engine through the transaxle to the power take-off unit (PTU). The PTU transfers engine power from the transaxle to the front halfshafts, and through the driveshaft to the active torque coupling/rear axle and halfshafts
The engine angle is built into the engine mounts. If the engine angle is out of specification, the engine mounts must be inspected for damage.
Vehicle Certification (VC) Label Example:
The Vehicle Certification (VC) label is located in the driver doorjamb. The axle code is on the VC label.
The axle ratio is 2.93 and the ring gear has a diameter of 174 mm (6.85 inch).
The wheel speed sensor rings for vehicles are located on the front halfshafts and are mounted to the rear inner spindles.
The wheel speed sensor rings are located on the front and rear halfshafts for 4WD vehicles.
Driveshaft
CAUTION: All driveshaft assemblies are balanced. If undercoating the vehicle, protect the driveshaft to prevent overspray of any undercoating material.
CAUTION: Manual and automatic transmission, as well as 3.0L and 2.3L engine, driveshafts are different. Make sure that the driveshaft being installed is compatible with the vehicle or damage to the vehicle may occur.
The driveshaft has traditional balance weights attached (spot-welded) by the manufacturer.
Universal Joints
The front joint is replaced with the driveshaft.
The center and rear joints are:
^ a lubed-for-life design that requires no periodic lubrication.
^ equipped with nylon thrust washers located at the base of each bearing cup which control end play, position the needle bearings and improve grease movement.
Rear Drive Axle and Differential
The active torque coupling/rear axle is serviced as an assembly.
The differential housing cover uses a silicone sealant rather than a gasket.
Each halfshaft is held in the differential case by a driveshaft bearing retainer circlip that is located on the inner constant velocity (CV) Joint stub shaft pilot bearing housing. When each halfshaft is installed, the driveshaft bearing retainer circlip engages a slot in the differential side gear.
The rear drive axle operates as follows:
^ The rear drive axle pinion receives power from the engine through the transaxle, transfer case, driveshaft and active torque coupling, and is always engaged.
^ The pinion gear rotates the differential case, which is bolted to the differential case outer flange.
^ Inside the differential case, 2 differential pinion gears are mounted on a differential pinion shaft that is pinned to the differential case.
^ These differential pinion gears are engaged with the differential side gears, to which the halfshafts are splined.
^ As the differential case turns, it rotates the halfshafts and rear wheels.
^ When it is necessary for one wheel and halfshaft to rotate faster than the other, the faster turning differential side gear causes the differential pinion gears to roll on the slower turning differential side gear. This allows differential action between the 2 halfshafts.
Front Drive Halfshafts
The front drive halfshafts consist of the following components:
^ Inner CV joints
^ Outer CV joints
^ Intermediate shaft/bearing
^ Halfshafts
The intermediate shaft bearing is pressed on and is only serviced as an assembly with the intermediate shaft.
Halfshaft Joint
The front drive halfshaft joints consist of the following components:
^ Inner CV joints
^ Outer CV joints
^ CV joint boot clamps
^ CV joint boots
^ Tripod joint housings
^ Retainer circlips
Rear Drive Halfshafts
CAUTION: An inspection of the outer and inner CV joint boots is necessary so that if damage or grease leakage is evident, installation of a new halfshaft can take place immediately. Continued operation with damage or grease leakage will result in CV joint wear and noise due to contamination and loss of the CV joint grease.
^ The inner and outer CV joints connect to a splined shaft. A circlip holds the cross groove inner race assembly (inner CV joint) together.
^ The RH and LH halfshafts are the same length.
^ An axle circlip retains the splined inner CV Joint to the differential side gear. Install a new axle circlip each time the halfshaft is removed from the vehicle.
^ A rear axle wheel hub nut secures the side shaft assembly (interconnecting shaft and outer CV joint) to the rear wheel hub. Install a new rear axle wheel hub nut each time the halfshaft is removed from the vehicle.
Halfshaft Handling
CAUTION: Never pick up or hold the halfshaft by only the inner or outer CV joint.
CAUTION: Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the CV joints.
CAUTION: Do not over-angle the CV joints.
CAUTION: Damage will occur to an assembled inner CV joint if it is over-plunged outward from the joint housing.
CAUTION: Never use a hammer to remove or install the halfshafts.
CAUTION: Never use the halfshaft assembly as a lever to position other components. Always support the free-end of the halfshaft.
CAUTION: Do not allow the boots to contact sharp edges or hot exhaust components.
CAUTION: Do not drop assembled halfshafts. The impact may cut the boots from the inside without evidence of external damage.
Handle all halfshaft components carefully during removal and installation procedures.