Differential Assembly: Testing and Inspection

DIAGNOSIS AND TESTING - NOISE

FLUID CHECK

To check axle fluid, park vehicle on a level surface. Take a piece of wire (or pipe cleaner) and make a 90 degree bend two inches from the end of the wire. Insert the wire into the fill plug hole and use it like a dipstick. Remove the wire and measure from the 90 degree bend to the oil level. Refer to specification for the correct measurement.

GEAR NOISE

Axle gear noise can be caused by insufficient lubricant, incorrect backlash, incorrect pinion depth, tooth profiles, or worn/damaged gears.

Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving condition. These conditions are acceleration, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the noise stops or changes greatly check for:

- Insufficient lubricant.
- Incorrect ring gear backlash.
- Incorrect pinion shim.
- Gear damage.

Differential side gears and pinions can be checked by turning the vehicle. They usually do not cause noise during straight-ahead driving when the gears are not rotating. The side gears rotate during vehicle turns. A worn pinion shaft can also cause a snapping or a knocking noise.

BEARING NOISE

The axle shaft, differential and pinion bearings can all produce noise when worn or damaged. Bearing noise can be either a whining, or a growling sound.

Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion bearing noise will be higher pitched because it rotates at a faster rate. While driving the vehicle and lightly applying the accelerator, load the differential by lightly applying the brakes. If bearing noise occurs, the rear pinion bearing is the source of the noise. If the bearing noise is heard during a coast, the front pinion bearing is the source.

Differential bearings usually produce a low pitch noise. Differential bearing noise is similar to pinion bearing noise. The pitch of differential bearing noise is also constant and varies only with vehicle speed and usually starts at higher speed.

Axle shaft bearings produce noise and vibration when worn or damaged. The noise generally changes when the bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and to the right. This will load the bearings and change the noise level. Where axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 mph.

LOW SPEED KNOCK

Low speed knock is generally caused by:

- Worn U-joint.
- Worn side gear thrust washers.
- Worn pinion shaft bore.

VIBRATION

Vibration at the rear of the vehicle is usually caused by a:

- Damaged drive shaft.
- Missing drive shaft balance weight(s).
- Worn or out-of-balance wheels.
- Loose wheel lug nuts.
- Worn U-joint(s).
- Loose/broken springs.
- Damaged axle shaft bearing(s).
- Loose pinion gear nut.
- Excessive pinion yoke run out.
- Bent axle shaft(s).

Check for loose or damaged front-end components or engine/transmission mounts. These components can contribute to what appears to be a rear end vibration. Do not overlook engine accessories, brackets and drive belts.

NOTE: All driveline components should be examined before starting any repair.

DRIVELINE SNAP

A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged), can be caused by:

- High engine idle speed.
- Transmission shift operation.
- Loose engine/transmission/transfer case mounts.
- Worn U-joints.
- Loose spring mounts.
- Loose pinion gear nut and companion flange.
- Excessive ring gear backlash.
- Excessive side gear to case clearance.

The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the vehicle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear. Listen for the noise, a mechanics stethoscope is helpful in isolating the source of a noise.

DIAGNOSTIC CHART