Abstract: A drive system for an electric vehicle includes a housing having a first housing portion, a second housing portion connected to the first housing portion, and a third housing portion connected to the second housing portion. The third housing portion includes a torque arm connectable to a vehicle chassis. A hypoid gear set is mounted in the first housing portion, and an electric motor is mounted in the third housing portion.

Abstract: A drive system for an electric vehicle includes a housing having a first housing portion, a second housing portion connected to the first housing portion, and a third housing portion connected to the second housing portion. The third housing portion includes a torque arm connectable to a vehicle chassis. A hypoid gear set is mounted in the first housing portion, and an electric motor is mounted in the third housing portion.

Abstract: A bevel gear set and a method of manufacturing the same are provided. The bevel gear set may include a first bevel gear and a second bevel gear. The first and second bevel gears may be spiral bevel gears or hypoid spiral bevel gears. The first and second bevel gears may each have a gear tooth surface having a plurality of teeth formed thereon, such that the teeth of the first bevel gear and the teeth of the second bevel gear are configured to engage in a meshing engagement. The teeth are machined onto the respective gear tooth surface via a face milling process. Each tooth includes a tooth top, a plurality of meshing surfaces, and at least one chamfer. The chamfer may be formed at an abutment edge disposed between the tooth top and a respective meshing surface via a brushing process directly following the machining of the teeth.

Abstract: A bevel gear set and a method of manufacturing the same are provided. The bevel gear set may include a first bevel gear and a second bevel gear. The first and second bevel gears may be spiral bevel gears or hypoid spiral bevel gears. The first and second bevel gears may each have a gear tooth surface having a plurality of teeth formed thereon, such that the teeth of the first bevel gear and the teeth of the second bevel gear are configured to engage in a meshing engagement. The teeth are machined onto the respective gear tooth surface via a face milling process. Each tooth includes a tooth top, a plurality of meshing surfaces, and at least one chamfer. The chamfer may be formed at an abutment edge disposed between the tooth top and a respective meshing surface via a brushing process directly following the machining of the teeth.

Abstract: An axle assembly having a differential gear set is provided. The axle assembly includes a housing having an interior portion sized to receive the differential gear set. At least one axle tube extends from a side of the housing. At least one axle is coupled to the differential gear set and extending through the at least one axle tube. A lubrication control member is coupled between the axle and the housing, the lubrication control member having at least one orifice, the orifice defining a lubrication flow path between the interior portion and the at least axle tube.

Abstract: A front axle shift mechanism configured to be operably associated with a front axle housing having a front differential and a first lubricant is provided. The front axle shift mechanism includes a disconnect feature housing defining an inner cavity to house a shifting mechanism configured to selectively provide power to front wheels of the vehicle, the shifting mechanism configured to rotatably couple to the front differential. The inner cavity is configured to receive a second lubricant to facilitate providing lubrication to the first clutch gear and the second clutch gear. The second lubricant is fluidly separate from the first lubricant.

Abstract: An axle housing for an axle assembly of a vehicle includes a pinion portion and a differential portion. The differential portion rotatably supports a differential gear assembly. A pinion insert has a first and second bearing pockets and is disposed in the pinion portion of the axle housing at least partially forming a bore through which a pinion shaft rotates. A first bearing is disposed in the first bearing pocket of the pinion insert and a second bearing is disposed in the second bearing pocket of the pinion insert. The pinion insert is manufactured from a material having a higher stiffness than the cast metal alloy of the axle housing.

Abstract: A front axle shift mechanism configured to be operably associated with a front axle housing having a front differential and a first lubricant is provided. The front axle shift mechanism includes a disconnect feature housing defining an inner cavity to house a shifting mechanism configured to selectively provide power to front wheels of the vehicle, the shifting mechanism configured to rotatably couple to the front differential. The inner cavity is configured to receive a second lubricant to facilitate providing lubrication to the first clutch gear and the second clutch gear. The second lubricant is fluidly separate from the first lubricant.

Abstract: An axle assembly having a differential gear set is provided. The axle assembly includes a housing having an interior portion sized to receive the differential gear set. At least one axle tube extends from a side of the housing. At least one axle is coupled to the differential gear set and extending through the at least one axle tube. A lubrication control member is coupled between the axle and the housing, the lubrication control member having at least one orifice, the orifice defining a lubrication flow path between the interior portion and the at least axle tube.

Abstract: A rotating machine has a splined primary shaft rotatably mounted in an opening of an oil-filled housing and a primary seal carried by the housing for sealingly engaging with a mating splined secondary shaft upon insertion of the secondary shaft into the housing opening for engagement with the splined primary shaft. An annular seal is also carried by the housing and has a flexible sealing lip for sealing engagement with the primary shaft to maintain oil within the housing. The annular seal has an abutment lever which extends toward the opening to be engaged by the splined secondary shaft upon insertion of the secondary shaft through the housing opening to forcibly pivot the flexible sealing lip of the annular seal away from sealing engagement with the primary shaft and thereby permit oil to flow to lubricate the splines between the primary and secondary shafts.