CarTech®
CarTech®, Inc.
39966 Grand Avenue
North Branch, MN 55056
Phone: 651-277-1200 or 800-551-4754
Fax: 651-277-1203
© 2009 by Joseph Palazzolo
All rights reserved. No part of this publication may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without prior permission from the Publisher. All text, photographs, and artwork are the property of the Author unless otherwise noted or credited.
The information in this work is true and complete to the best of our knowledge. However, all information is presented without any guarantee on the part of the Author or Publisher, who also disclaim any liability incurred in connection with the use of the information and any implied warranties of merchantability or fitness for a particular purpose. Readers are responsible for taking suitable and appropriate safety measures when performing any of the operations or activities described in this work.
All trademarks, trade names, model names and numbers, and other product designations referred to herein are the property of their respective owners and are used solely for identification purposes. This work is a publication of CarTech, Inc., and has not been licensed, approved, sponsored, or endorsed by any other person or entity. The Publisher is not associated with any product, service, or vendor mentioned in this book, and does not endorse the products or services of any vendor mentioned in this book.
Edit by Paul Johnson
Layout by Sue Luehring
ISBN 978-1-61325-253-6
Item No. SA355
Library of Congress Cataloging-in-Publication Data
Palazzolo, Joseph.
High-performance differentials, axles, and drivetrains / by Joseph Palazzolo.
p. cm.
1. Automobiles--Power trains. 2. Automobiles--Differentials. 3. Automobiles--Axles. I. Title.
TL260.P335 2009
629.2’45--dc22
2009021474
10 9 8 7 6 5
Title Page:
A high-performance axle assembly with gears and components matched to the transmission and engine will provide superior performance.
Back Cover Photos
Top Left:
The Ford 9-inch Banjo-style axle has a cast center section that is painted black and is removed from the front of the axle housing. A series of weld seams joins the multiple pieces together that eventually make up the entire beam portion of the housing.
Top Right:
The removable center section from the banjo-style axle looks like this. The adjuster nuts on either side of the differential allow for easier adjustment of the ring gear backlash and bearing preload. (GKN Driveline)
Middle Left:
This differential is being disassembled. Once the spring plates are partially pushed out, you can grab them with a suitable set of pliers. Compress the springs and the plates, and the springs should pull out.
Middle Right:
This cutaway shows how a viscous device acts across an axle differential. There are a large number of viscous shear plates on the right side of the part. These are sealed from the rest of the axle components so they are separated from the highly viscous silicon fluid. (GKN Driveline)
Bottom Left:
The hypoid gear arrangement shows the vertical offset of the pinion in relation to the ring gear centerline. In a common automotive application, the pinion resides below the ring gear centerline.
Bottom Right:
When the axle shaft C-washer is in place inside the differential, the C-washer fits inside the counterbored pocket in the side gear. This C-washer shows signs of wear but can be returned to service.
OVERSEAS DISTRIBUTION BY:
PGUK
63 Hatton Garden
London EC1N 8LE, England
Phone: 020 7061 1980 • Fax: 020 7242 3725
Renniks Publications Ltd.
3/37-39 Green Street
Banksmeadow, NSW 2109, Australia
Phone: 2 9695 7055 • Fax: 2 9695 7355
Dedication
To my beautiful wife, Kathy, and our twin sons, Adrian and Christian. May you follow your dreams as you have allowed me.
CONTENTS
Chapter 1: Rear Axle Fundamentals
Finding the Right Parts and Service