Failure Analysis and Maintenance Assessment of Differential Systems in Automobile Power Transmission

Abstract

The differential is one of the most critical components of an automobile power transmission system, responsible for transmitting torque from the driveshaft to the drive wheels while allowing them to rotate at different speeds during cornering. Due to continuous exposure to varying loads, shock impacts, inadequate lubrication, and harsh operating conditions, differential systems are susceptible to several failure modes that can significantly affect vehicle performance, safety, and maintenance costs. This study presents a comprehensive assessment of failure mechanisms in automobile differential systems and evaluates suitable maintenance strategies for improving reliability and service life. Common failures including gear tooth wear, pitting, scuffing, bearing failure, shaft fatigue, seal leakage, overheating, and lubricant degradation are analyzed using Failure Mode and Effects Analysis (FMEA). Maintenance approaches such as preventive, predictive, condition-based, and reliability-centered maintenance are compared to determine their effectiveness in reducing unexpected failures. The study concludes that regular lubricant monitoring, vibration analysis, thermal inspection, and scheduled maintenance significantly improve differential reliability while reducing downtime and maintenance expenditure.