Differentials: Identification, Restoration & Repair

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Item # RPS-26617  ISBN: 9781424326617

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Updated version expected end of January 2010

While the average repair manual will cover most automotive systems, when it comes to differential repair, information can range from overly complex to scant to missing altogether, and while manuals intended for the professional technician are much better, they may be difficult for the novice mechanic to follow.

Differentials: Identification, Restoration & Repair provides comprehensive coverage with details, tips, tricks, as well as performance modifications, presented in a fashion that allows the average do-it-yourselfer to perform the work at home on all common style of axles.

However, as complete as this manual is, front-wheel drive and transaxles are not covered by this book. Independent suspensions of rear-drive 4x2s and the front or rear of 4x4s are part of the discussion, but only the parts that transmit torque. These include the differential and possibly the CV-type axle shafts. Solid front axles of 4x4s are covered in detail.

Table of Contents

CHAPTER 1: AXLE 101
What is a Drive Axle? | Understanding Gearing | What've I Got? (Determining Axle Ratios) | The Flow of Torque and Differential Operation | Construction Details and Types | Axle Capacity | Semi-Float vs Full-Float | Axle Bearing Types | Axle Shaft Types | Integral vs Removable Carriers | Front Axles | Independent Suspension Drive Axles | Housing Construction Details | Axle Shaft Construction Details | Ring and Pinion Construction Details | Differential Construction Details | Common Steel Groups for Axles | Metal Treatments | In the Beggining... | Early Differentials | Early Axle Designs | Early Lockers and Limited Slips

CHAPTER 2: AXLE ENCYCLOPEDIA
The OE Axle | The Aftermarket Axle | Axle Identification by the Numbers | Determining Axle Ratios and Traction Aids | When All Else Fails | Chrysler Codes | Dana Codes | Ford Codes | GM Codes | Jeep/AMC Codes | Toyota Codes

Axle Encyclopedia

• AAM 9.25
• AAM 10.50 (new style)/11.50 Rear
• AMC-20 Rear
• Chrysler 7.9/8.0 IFS
• Chrysler 7.25 IFS, Chrysler 7.25 Rear
• Chrysler 8.25/8.375 Rear, Chrysler 9.25 Rear
• Chrysler 8.75
• Chrysler 9.63 Dropout
• Dana 28TTB/35 TTB/35 IFS
• Dana 25/27/30 Front, Dana 30 IFS
• Dana 44 Front, Beam & TTB
• Dana 50 Beam & TTB
• Dana 60, Dana 70 Front
• Dana 23, 27 and 30 Rear
• Dana 35/AMC-15 Rear
• Dana 36 ICA Rear/Dana 44 ICA Rear
• Dana 41, 44 and 45 Rear
• Dana 53/Dana 60/Dana 61 Rear
• Dana 70 Rear
• Dana 80 Rear
• Ford 7.5
• Ford 8.8
• Ford 8.0/9.0/9.38 Dropout
• Ford 9.75/10.25/10.50
• GM 7.25/8.25/9.25 IFS
• GM 8.5 Front
• GM 6.5/7.5/7.63/8.0
• GM 8.40 Rear Dropout
• GM 8.2/8.5/8.6 Rear
• GM 8.875 Car/Truck Rear
• GM 9.375 Rear Dropout
• GM 9.5 Rear
• GM H-052, H-072 Rear Dropouts
• GM 10.50 Rear
• Buick, Oldsmobile, Pontiac 8.2, 8.5, 9.30
• Samurai/Sidekick 6.90 Front/Rear Dropout
• Toyota 9.5 Dropout Front and Rear
• Toyota 7.5 IFS, 8.0 and 8.25-inch Dropouts, Front and Rear

CHAPTER 3: BUILDING BLOCKS
Tools | The Right Tools | Work Environment | Safety | Cleanliness | Light | Reasonable Comfort | Shop Supplies | Cleaning Materials | Cleaning Standards | Lubricants | Gear Oil Grades | Thread Lockers | Sealants | Nuts and Bolts | Ordering Parts | Break-In of New Parts | Bearings | Bearing Anatomy | Bearing Preload | Bearing Maintenance | Removing and Replacing Bearings | Bearing Inspection | Bearing Adjustments | Seals | Seal Anatomy | Basic Seal Inspection | 10 Steps to Successful Seal Installation

CHAPTER 4: LIGHT REPAIRS
Seals & Related Repairs | Replacing Pinion Seal and/or Pinion Yoke | Sealing a Diff Cover | Installing a Speedi-Sleeve | Front Axle Repairs and Service | Knuckle Repair: Closed Knuckle Axles | Knuckle Repair: Open Knuckle Axles | Replacing an Axle U-Joint | Autopsy: Inspecting Front Axle Shafts and U-Joints | Repacking Front Wheel Bearings | Locking Hub R&R | Live Spindle Axle & Bearing R&R | Axle Shafts, Bearings & Seals | C-Clip Axle | Pressed Bearing Flanged Axle | Full-Float Axle | Pressed Bearing Tapered Axle | Packing a Pressed Axle Bearing | Chrysler Adjustable Wheel Bearing Axles

CHAPTER 5: MAJOR REPAIRS
Major Repairs | What to Replace? | Disassembly, Cleaning and Inspection | The Bad and the Ugly | Disassembly | Cleaning | Ring, Pinion and Carrier Operations | Differential Repair | Using the Randy's Ring & Pinion Bearing Removel Tool | Ring & Pinion Replacement | Pinion Installation | Using a Pinion Depth Tool | Measuring Pinion Bearing Preload | Carrier Assembly | Using Randy's Ring & Pinion Case Spreader | Common Carrier Bearing Preload Shim Thicknesses | Reading and Adjusting the Ring & Pinion Tooth Pattern | Acceptable Patterns | Pinion is Too Close | Pinion is Too Far Away | Using a Dial Indicator | IFS Front Diffs | GM 8.25

CHAPTER 6: MODIFICATION 101
Why Modify? | Preplanning Modifications | Gearing | Gearing for Acceleration Performance | Acceleration vs Freeway Cruising | Gearing for Top Speed | Gearing for Towing Performance | Choosing a Towing Ratio | Gearing for 4x4/Trail Performance | Gearing for Economy | Building for Strength | Torque Capacity | Anatomy of a Strong Axle Shaft | Load Capacity | Street Performance Axle Buildup Tips | Axle Shaft Strength Chart | U-Joints 101 | Four Wheeling Axle Buildup Tips | 4x4 Front Axle Tips, Solid Axles | Super Strength U-Joints | 4x4 Front Axle Tips, IFS Axles | 4x4 Front Axle Tips, TTB Axles | Performance Traction | Limited Slips | Plate Clutch Type Limited Slip | Cone Clutch Type Limited Slips | Gear Type Limited Slips | Limited Slip Characteristics Evaluation | Lockers | Automatic Lockers | On-Demand Lockers | Spools: Applications, Traction, Strength and Manners Rating | Traction Aid Evaluations | Tractech: Detroit Locker, Truetrac, E-Z Locker, Electrac | Auburn: High Performance Series, Pro Series, ECTED | ARB: ARB Air Locker | Power Trax: Lock Right Locker, No Slip Locker | Eaton: Eaton Posi (New Generation), Eaton E-Locker | Dana: Powr-Lok Limited Slip, Trac-Lok Limited Slip | Ford/Visteon: Traction Lok | Torsen: T-1 | Ox Brand: Ox Locker | Yukon Gear: DuraGrip | DuraGrip TL, Yukon Performance Powr-Lok | Other Lockers/Limited Slips: KAM Differentials Limited, Quaiffe, Indianapolis Custom Products | Stuff You Might Not Have Thought About

CHAPTER 7: UPGRADE POTPOURRI
Traction Aid Overhaul and Upgrade | Checking Limited Slip Operation: Dana Powr-Lok Overhaul/Upgrade, Dana Trac-Lok Overhaul/Upgrade, Eaton Posi Overhaul/Upgrade, Ford Traction-Lok and Yukon DuraGrip T/L Overhaul | Locker and Limited Slip Installation: ARB Air Locker, Power Trax Lock Right Installation, Full Spool Installation, Mini-Spool Installation | A Selection of Improvements: Cover Girdle, Crush Sleeve Eliminator, AMC-20 One-Piece Axle, Yukon Super Joints | Axle Swapping Tips | Grinding and Deburring | Speedometer Correction

Appendix 1: Glossary (Gearhead Dictionary) | Appendix 2: Formulas

Differentials: Identification, Restoration & Repair