Axle Assemblies

The drive axle assembly connects the drive wheels to the driveshaft. It takes the power from the engine that is conducted through the transmission and driveshaft, turns it 90 degrees using the differential and hypoid gearset contained within, and transmits it to the drive wheel and tire assemblies via axle shafts. A drive axle can be mounted to the vehicle frame and used with an independent suspension system or be a “live” axle that is attached to suspension members, moving up and down as the suspension reacts to road irregularities. No matter what type of drive axle is on your vehicle, if you’re experiencing leaks, noise or any other symptoms warranting repair, you’ll find replacement axles that will restore performance, reliability and quiet operation right here on our digital shelves. We also a comprehensive array of top-notch axle assemblies made to provide the next level of off-road performance for your vehicle.

The ring and pinion gears that comprise the hypoid gearset not only take the rotational motion of the driveshaft and direct it at right angles to turn the axle shafts, they also multiply engine torque through the gear ratio, the number of teeth on the ring gear divided by the number of teeth on the pinion gear. The pinion gear is located in an opening in the differential housing where it rotates on tapered roller bearings. It’s secured by the pinion yoke, which also serves as the mount for the driveshaft U-joint. The ring gear is mounted to the differential case, which also rotates on tapered roller bearings, and is situated in the differential housing so its centerline and the bearings are aligned with the axle shafts and the ring gear meshes properly with the pinion gear. Shims or adjusters are used to set the ring and pinion contact pattern and backlash.

The differential allows the outside and inside wheels to rotate at different speeds when the vehicle turns a corner. The axle shafts enter the differential case through the side bearings, where they are splined to the side gears, which are part of the spider gears that allow the wheels to turn at different speeds. The spider gears consist of 2 pinion gears and the 2 differential side gears. The pinion gears turn on the pinion shaft, which is fitted to the inside of the differential case. The differential side gears mesh with the pinion gears. When the vehicle travels straight ahead, the pinion rotates with the differential case and all gears rotate as a unit, transferring motion to the drive axles.

When the vehicle turns, the inside wheel turns more slowly than the outside wheel, so the pinion gears then rotate on the pinion shaft, turn on the slower turning axle and drive the outside axle at a greater speed. Unfortunately, this type of differential, commonly known as an “open” differential, directs power to the wheel with the least traction, allowing it to spin while the tire on the opposite side that has traction gets no power. Some vehicles have clutch type, geared, viscous, or electronic limited slip, also called positraction, differentials, which operate like an open differential so the vehicle can go around corners, but can also transmit equal power to both wheels even when traction between wheels varies.

The frame mounted axle assemblies used with independent suspensions may consist of little more than a housing for the differential and ring and pinion gears. Short axles called stub shafts connect the differential side gears to the wheels with halfshafts and CV Joints that rise and fall with suspension movement. The differential housing on live axles, sometimes called “solid” axles, may bolt on or be integral with the axle housing. One-piece axle shafts that are splined to the side gears and mount to the wheels are contained within axle tubes. Both the tubes and differential housing provide mounting points for suspension members. The semi-floating axle shafts on cars and light trucks transmit power and support the weight of the vehicle. They may be retained inside the differential with C-clips and rotate on roller bearings pressed into the axle tubes, or bolt to the axle tubes and have bearings pressed onto the shafts. The full floating axles on heavy-duty trucks only transmit power. They rotate on bearings that are in a hub outside the axle housing.

Axle assemblies can leak at the pinion seal, differential housing-to-axle housing gasket, differential cover gasket, and at the stub shaft or axle shaft seals. All gaskets and seals can develop leaks due to heat and age but pinion, stub shaft and axle seals can also leak because of excessive bearing play. Howling or whining noise from the axle assembly can be caused by worn ring and pinion gears or by improper tooth contact due to bearing wear or incorrect set-up. Damaged side gears and pinion gears inside the differential case can make a clunking sound. The clutch packs in limited slip differentials can chatter when cornering if the incorrect lubricant is used. A worn axle bearing can cause a growling noise.

Some of the above defects can be easily repaired but others require extensive disassembly, parts expense, and precision measurements during installation. Even relatively simple jobs can become more involved. For example, the bearing contact surface on some axle shafts can wear, axles can become bent from wheel/tire contact with obstacles like curbs, and axle shaft splines can twist when exposed to excessive loads, complicating what started out as a routine bearing and seal replacement. Instead of repairing a high-mileage axle assembly with multiple problems, at great expenditure of time and cash, installing one of our replacement, bolt-in, axle assemblies backed by a substantial warranty is the faster, more economical, and smarter solution.

No matter what you’re working on, what axle ratio you need, or whether you require an open or limited slip differential, we have the replacement axle assembly that will restore performance and durability. We offer remanufactured axle assemblies that are assembled according to original equipment specifications, so when repairs are completed you can count on the performance your vehicle was designed to deliver. On our website we also have an enormous assortment of prime axles assemblies carefully designed for astounding performance while driving through rocky terrain, sand deserts or muddy roads. By providing unmatched rigidity and durability they can withstand the most demanding off-road conditions. The axle assemblies are manufactured using the very latest technology and equipment to ensure seamless user experience. They are crafted from top-grade materials to maintain the high level of toughness and resiliency needed for challenging landscapes. The innovative improvements of the axle assemblies we offer will give you the advantage when driving across even the most brutal terrain.