Abstract: In at least one implementation, a method of assembling gears into a housing of an automotive differential includes, selecting a thickness dimension of first and second pinion gear washers, and first and second side gear washers, locating a pair of pinion gears, a pinion shaft and a pair of side gears at least partially within an interior of the housing with the pinion gear washers between the housing and separate ones of the pinion gears, and the side gear washers between the housing and separate ones of the side gears. The thickness of the side gear washers may be a function of target side gear apex positions and relative to a pinion gear apex axis. The thickness of the pinion gear washers may be a function of target pinion gear apex positions residing along a pinion gear apex axis and relative to a side gear apex axis.

Abstract: In at least some implementations, a system for a vehicle differential having multiple gears includes a coil of wire, a drive member movable in response to a magnetic field generated by application of electricity to the coil between a first position and a second position, and a lock member coupled to the drive member for movement with the drive member throughout a range of movement of the drive member. The lock member is adapted to engage a gear of the differential when the drive member is in the second position and the lock member is adapted to be disengaged from the gear when the drive member is in the first position. In this way, the differential may be selectively locked.

Abstract: In at least some implementations, a torque transmitting apparatus includes a first member arranged for rotation about an axis and having a first surface oriented substantially perpendicular to the axis, and a second member having a second surface with at least a portion that is parallel to and engaged with at least a portion of the first surface. The second member is coupled to the first member by a weld provided in an interface region defined by an area of radial overlap between the first surface and the second surface. The groove is provided in one or both of the first surface and the second surface, the groove has a portion located radially inboard of the weld and at least one outlet that, at least without the weld, is communicated with a radially outer edge of the interface region.

Abstract: A system is described, as well as methods of using the system. The method includes: determining an error within the vehicle driveline system; following the error, determining that a state of a power take-off unit (PTU) within the system is determinable; and then transferring a normal torque from the PTU to a secondary drive unit (SDU) during the error.

Abstract: In at least some implementations, a system for a vehicle differential having multiple gears includes a coil of wire, a drive member movable in response to a magnetic field generated by application of electricity to the coil between a first position and a second position, and a lock member coupled to the drive member for movement with the drive member throughout a range of movement of the drive member. The lock member is adapted to engage a gear of the differential when the drive member is in the second position and the lock member is adapted to be disengaged from the gear when the drive member is in the first position. In this way, the differential may be selectively locked.

Abstract: A system for a vehicle differential includes a magnetic field generator, a drive member and a lock member. The drive member is movable in response to a magnetic field between a first position and a second position, and the drive member has at least one contact surface. The lock member adjacent to the drive member and having at least one contact surface that is engaged by at least one contact surface of the drive member so that the lock member is driven by the drive member to engage a gear of the differential when the drive member is in the second position, and the lock member is adapted to be disengaged from the gear when the drive member is in the first position. One or both of the drive member and the lock member has at least one contact surface that is discontinuous.

Abstract: In at least some implementations, a vehicle differential includes a housing having a mounting flange with multiple openings through the flange, an annular gear mounted to the flange by a plurality of fasteners received through the openings, a coil received radially inwardly of the fasteners, and a coupler. The coupler is fixed to the housing and engaged with the coil to retain the position of the coil relative to the housing, and the coupler extends into an area between adjacent fasteners, where the area is circumferentially between adjacent fasteners and radially overlapped with at least a portion of the adjacent fasteners.

Abstract: A system for a vehicle differential includes a coil and a drive member movable between a first position and a second position. The drive member has an axis and includes a first body that is magnetically responsive, a second body formed at least partially from a second material that is not magnetically responsive and a third body that defines a radially inner surface of the drive member. The first body, second body and third body are coupled together with the third body being formed from a material having a lower coefficient of thermal expansion than the second body. The system may also include a lock member driven by the drive member to engage a gear of the differential in at least one position of the lock member.

Abstract: A retainer for coupling rotating shafts includes a body and a finger. The body may have a curved section extending in a circumferential direction about an axis and a pair of ends. The finger extends from the body and has a least a portion that extends inwardly toward the axis. The finger may be flexible and resilient and have an at rest state and a second state wherein the finger flexes outwardly away from the axis when acted upon by a sufficient force, and the finger returns toward its at rest state when the force is reduced or removed from the finger. When a second shaft is partially inserted into a first shaft, an object may engage and flex the finger until the object passes by the finger whereupon the finger may return toward the at rest state partially overlapping the object.

Abstract: In at least some implementations, a system for a vehicle differential that has multiple gears may include a coil, a drive member movable in response to a magnetic field generated by application of electricity to the coil and a lock member driven by the drive member to selectively engage a gear of the differential. The drive member is movable between a first position and a second position, has an axis and includes a first body formed at least partially from a first material that is magnetically responsive and a second body formed at least partially from a second material. The first body and second body are coupled together and overlapped in two opposing axial directions to limit or prevent relative axial movement between the first body and the second body.

Abstract: A process of controlling an actuating assembly for a coupling in the driveline of a motor vehicle, wherein the actuating assembly comprises a drive for moving an actuating element for operating the coupling unit, sensing a position signal representing the position of the actuating element; sensing a force signal representing the operating force required for displacing the actuating element; controlling the drive by means of an electronic control unit as a function of the position signal and the force signal. Further an actuating assembly is used for carrying out the process, as well as a drive assembly having such an actuating assembly.

Abstract: A coupling assembly comprises a coupling which is arranged between a driving gear and a differential drive; a controllable actuator for actuating the coupling; a sensor for determining switching positions of the coupling; and a target element which cooperates with the sensor, wherein the target element is axially moved upon actuation of the actuator; wherein a first coupling part of the coupling is connected to a differential carrier of the differential drive and wherein a second coupling part of the coupling is held in a rotationally fixed and axially movable way relative to a differential housing of the differential drive, and wherein the target element is secured to the second coupling part by a bayonet-type connection.

Abstract: A drive assembly for a motor vehicle has a multi-step transmission and a differential drive. The multi-step transmission comprises a rotatingly drivable driveshaft and an intermediate shaft parallel to the driveshaft, and at least one first transmission stage and a second transmission stage for transmitting torque from the driveshaft to the intermediate shaft with different transmission ratios, as well as a shift unit, wherein the intermediate shaft comprises an output gear for transmitting torque to a differential carrier of the differential drive, wherein a rotational axis of the differential carrier extends parallel to the intermediate shaft, wherein the output gear and the shift unit are arranged axially between the at least two transmission stages, and wherein the driveshaft comprises bores for supplying lubricant.

Abstract: A plate carrier for a multi-plate clutch comprises: an annular member with a first circumferential face and a second circumferential face; a toothing in the first circumferential face of the annular member, having circumferentially distributed teeth and gaps; at least one groove in the second circumferential face of the annular member, wherein the groove extends over a circumferential portion of the annular member, wherein the groove and the toothing intersect one another, so that radial apertures are formed in the regions of intersection between the groove and the tooth gaps. A multi-plate clutch can be provided with such a plate carrier.

Abstract: A method for operating a drive train of a vehicle having a clutch assembly, in particular for distributing torque to a primary axle and a secondary axle of the vehicle and/or for distributing torque between two wheels of one axle of the vehicle, comprises at least the following steps: a) determining temperature data at least from an electronic control unit which is assigned to the clutch assembly, or from an actuation unit of the clutch assembly; b) evaluating the temperature data determined in step a); and c) reducing an effective value of a control current at least of the electronic control unit or of the actuation unit by pulsing the control current if the evaluation in step b) reveals that a temperature at least of the electronic control unit or of the actuation unit exceeds a threshold value.