Differential gear kits

Types of differential gear kits

Differential gear kits are an important part of four-wheel and rear-wheel drive vehicles. They help the wheels to rotate at different speeds, especially when turning corners. Without a differential, the wheels would all turn at the same speed. This would cause the vehicle to skid or tip over, and it could damage the drivetrain. There are several types of differential gear kits, each with its own advantages and disadvantages.

• Open differential gear kits

  This is the most common type of differential and it comes as standard in most cars. It is simple and cheap to make. The open differential uses two half-shafts and a pinion gear to allow the wheels to rotate at different speeds. The left and right wheels are connected through a set of spider gears. When the vehicle turns a corner, the wheel on the outside of the turn rotates faster than the one on the inside. The spider gears spin between the two half-shafts and allow the wheels to rotate at different speeds. One disadvantage of open differentials is that it is hard to get out of a slippery surface like mud or snow. If one wheel starts to slip, the differential will send all the power to that wheel. The vehicle will not be able to move.

• Limited slip differential (LSD)

  A limited slip differential is a type of open differential. It has an extra mechanism to limit the speed difference between the two wheels. The LSD uses a clutch pack or spring-loaded preload to connect the two half-shafts. When the vehicle is driving normally, the clutch pack is not engaged, and the wheels can rotate at different speeds. But if one wheel starts to slip, the LSD engages the clutch pack. It transfers some of the torque from the slipping wheel to the other wheel. This helps the driver to get out of the slippery surface.

• Locking differential gear kits

  A locking differential is more advanced than the LSD. It can lock the two half-shafts together when needed. A locking differential uses a mechanical lever or an electronic actuator to connect the two half-shafts. The driver can choose to lock or unlock the differential using a switch or lever. When locked, both wheels spin at the same speed. This is useful when driving on very slippery or uneven surfaces like mud, snow, sand, or rocks. The locking differential gives more traction in off-road conditions. One disadvantage is that the locked differential can damage the drivetrain if used on hard surfaces like tarmac or concrete. This is because the wheels cannot adapt to uneven surfaces or changes in traction.

• Torque vectoring differential gear kits

  Torque vectoring differentials are the most advanced differential gear kits. They are found in high-performance sports cars and some hybrid and electric vehicles. The torque vectoring differential uses electronic controls to distribute torque to each wheel. It can send more power to the wheel that needs it the most. For example, during hard cornering, the differential can give more torque to the rear outside wheel. This improves grip and stability while reducing understeer. The torque vectoring differential uses sensors like wheel speed, yaw rate, and steering angle to monitor the vehicle's behavior. Based on the data, the electronic control unit (ECU) adjusts the torque distribution in real time. This differential gear kit improves performance, handling, and safety, especially in extreme driving conditions.

Specification & Maintenance of Differential Gear Kits

• Quality of Gear Material

  The differential gears are made with high-quality material. The gears are made from steel or iron. The materials are durable and strong. The gears can handle a lot of pressure and force without breaking. The gears also have a coating or treatment. The coating helps the gears resist wear and tear.

• Gear Size and Ratio

  The differential gears come in different sizes. The size affects the performance of the vehicle. A bigger gear gives more power but turns slowly. A smaller gear gives less power but turns fast. The gear ratio matches the needs of the vehicle. It also matches other parts like the transmission.

• Bearing Size and Type

  The bearings are an important part of the differential kit. The bearings help the gears turn smooth. The bearings come in different sizes. The size must match the differential housing and the gears. The bearings are also made in different types. Each type works better for a certain application.

• Case Type and Material

  The differential case holds all the parts together. The case is made from strong material like cast iron or aluminum. The type of case depends on the differential style. For example, a limited-slip diff has a special case for the clutch plates.

• Pinion and Ring Gear Size and Ratio

  The pinion and ring gears are used to set the ratio of the differential. The pinion gear is connected to the driveshaft. It spins the ring gear, which is connected to the axle. The size of the pinion and ring gears affects the torque and speed of the vehicle. A bigger ring gear gives more torque. A smaller pinion gear makes the vehicle faster. The sizes and ratios are planned to fit the needs of the vehicle.

• Washers, Spacers, and Shims

  These small parts help to set the right gaps between the gears and bearings. They also help to adjust the preload tension on the bearings. They come in different sizes to suit the specific differential gear kit.

It is important to maintain the differential gear kits for optimal performance and durability. Here are some tips for maintaining differential gear kits:

• 1

  Check the oil level and top it up if needed. Change the oil regularly. The oil keeps the gears lubricated and cool. Use high-quality oil made for differentials.

• 2

  Don't overload the vehicle. Excess weight can strain the differential. Be careful when towing or hauling heavy loads.

• 3

  Avoid spinning the wheels on slippery surfaces like ice or mud. This can damage the differential as all wheels must turn at the same speed.

• 4

  Listen for strange noises from the differential. If something sounds wrong, get it checked out before it becomes a bigger problem.

• 5

  Inspect the differential housing and seals for leaks or damage. Repair any issues right away to prevent water or dirt from getting inside.

• 6

  Don't let the vehicle sit unused for long periods. Exercise it every few weeks to keep the differential components moving freely.

• 7

  When replacing tires, use the same size, type, and tread pattern on all wheels. Mismatched tires can stress the differential gearing over time.

How to Choose Differential Gear Kits

Wholesale buyers should consider the following factors when choosing gear kits for differentials:

• Type of Kit

  As mentioned earlier, there are several types of differential gear kits. Each kit is ideal for a specific application. Therefore, buyers should understand the needs of their target customers before purchasing any kit. For instance, customers looking to boost the performance of their 4WD vehicles off the road will be interested in a high-performance gear kit.

• Brand

  Some manufacturers have established a name for themselves by producing quality aftermarket parts. Their products tend to have a high resale value. Additionally, the products come with quality assurance. Buyers should research the brands they want to purchase and ensure they are trustworthy.

• Material

  Materials used to manufacture the gears in the kits matter. Buyers should choose kits with gears made from high-quality materials. The material used affects the strength and durability of the gears. Most aftermarket gears are made from steel. However, some manufacturers use materials such as tungsten. Steel is preferred because it is long-lasting and can withstand harsh conditions.

• Gear Ratio

  Different kits have different gear ratios. The gear ratio in a differential kit determines the performance of a vehicle. Buyers should choose kits with various gear ratios. This is because different customers will have varying preferences. Some will want a gear kit that improves acceleration, while others will want a kit that enhances fuel efficiency.

How to DIY and Replace Differential Gear Kits

Replacing gears in a differential requires a dismantling process. The process can get messy, and professionals are recommended for the job. However, with the right expertise, below are some of the steps to follow when replacing the differential gear kit.

• Preparing the Vehicle

  Firstly, the car is lifted and secured on jack stands. The wheels, driveshaft, and axle are also disconnected. Secondly, the old oil is drained from the differential housing using a drain pan. This is done by removing the drain plug located at the bottom of the differential.

• Dismantling the Differential

  To get the differential gear out, the cover is removed from the housing. After that, the ring gear is separated from the case by removing the bolts that hold them together. The old carrier assembly is removed from the differential housing. This is done by removing the bearing caps and pushing the carrier out using a slide hammer.

• Installing the New Differential Gear Kit

  The new carrier assembly is installed in the differential housing. The bearing caps are torqued to the manufacturer's specifications. After that, the new ring gear is bolted onto the carrier and properly aligned with the pinion gear. This step is very crucial, as it determines the longevity of the gears.

• Reassembling the Differential

  Once the kit is properly installed, the differential is reassembled. This is done by putting the pinion gear into the yoke and then the shaft. After that, the flange is bolted onto the shaft. Finally, the differential housing is closed, and the oil is filled to the recommended level.

Q&A

Q1: What are the signs of a bad differential?

A1: There are several signs that indicate a bad differential. One of the most common is noise. When the differential is failing, it will produce noise such as grinding, clunking, or whirring sounds, especially when turning or accelerating. Another sign is difficulty in turning the vehicle, which occurs when the differential is locking or failing to distribute power between the wheels. Uneven tire wear, leaking fluid, and burning smells are other signs that indicate a bad differential gear.

Q2: Can a differential be repaired?

A2: Yes, a differential can be repaired. However, the repairability depends on the extent of the damage. If the gears or bearings are mildly worn out, they can be replaced. However, if there are numerous worn-out parts, it is more cost-effective to replace the differential rather than repair it.

Q3: Is it necessary to change the differential when changing the tires?

A3: No, it is not necessary to change the differential when changing the tires. However, it is important to ensure that all tires are replaced at the same time to maintain differential health. Using a tire with significantly different tread depth or diameter can strain the differential gear and lead to damage over time.

Q4: How often should differential maintenance be performed?

A4: Differential maintenance, such as fluid changes, should be performed according to the manufacturer's recommended interval, typically every 30,000 to 60,000 miles. However, before carrying out maintenance, differential gear buyers should consult the specific vehicle service manual for the correct maintenance schedule and service tips.