Abstract: An axle assembly that includes an axle housing assembly, a differential disposed in the axle housing assembly, an input pinion, a pair of axle shafts and a heat sink. The input pinion is coupled to the axle housing assembly and is configured to transmit a rotary input to the differential. The axle shafts are coupled to the differential and housed in the axle housing assembly. The heat sink is coupled to the axle housing assembly and is formed of a material having a thermal conductivity that is greater than that of the axle housing assembly. The heat sink does not consist entirely of a chrome plating, a zinc plating or a cadmium plating. A cover for an axle assembly is also provided.

Abstract: A method for lubricating an axle assembly can include: coupling a pair of tapered roller bearing to opposite ends of a differential housing; placing the differential housing into a carrier housing assembly such that the tapered roller bearings support the differential housing on the carrier housing assembly for rotation about a first axis; collecting a lubricant proximate a side of one of the tapered roller bearings opposite the differential housing; and rotating the differential housing about the first axis to cause the one of the tapered roller bearings to move a portion of the collected lubricant through the differential housing. A related axle assembly is also provided.

Abstract: An axle assembly with an axle housing assembly and a differential that is mounted in the axle housing assembly for rotation about a first axis. The axle housing assembly defines an interior cavity with a sump having a static liquid lubricant level. The axle housing assembly includes a housing structure and a cover that is coupled to the housing structure. First and second sets of ribs are coupled to the cover and extend into the interior cavity. The first and second sets of ribs are disposed on opposite sides of a ring gear associated with the differential and include a plurality of ribs. A first portion of at least one of the ribs extends below the static liquid lubricant level to thereby be immersed when a liquid lubricant fills the sump to a level that coincides with the static liquid lubricant level.

Abstract: An axle assembly that includes a housing assembly, a lubricant and a differential assembly. The housing assembly defines a differential cavity with a lubricant sump into which the liquid lubricant is received. The differential assembly is mounted in the differential cavity for rotation about a rotational axis and includes a differential case, a ring gear, a gear set and an oil shield. The differential case has a body, which defines a gear cavity into which the gear set is received, and a flange that is coupled to the body and includes a flange face. The ring gear is coupled to the flange. The oil shield is coupled for rotation to the differential case and covers a least a radially outward portion of the circumferentially discontinuous features so that they do not directly contact the liquid lubricant in the lubricant sump when the differential assembly rotates about the rotational axis.

Abstract: An axle assembly having a heat sink coupled to an axle housing assembly for ejecting heat from the axle assembly. The heat sink includes an air channel having a body coupled to the carrier housing assembly such that heat is conducted from the carrier housing assembly to the body of the air channel and an air passage formed in the body and having an open leading end and an open trailing end, the leading end being positioned relative to the carrier housing assembly to permit air flowing over the axle assembly when the axle assembly is in use to be received into the air passage such that heat is conducted from the body to the air flowing through the air passage, and the trailing end being positioned relative to the carrier housing assembly to permit air received in the air passage to be expelled through the trailing end.

Abstract: A method for lubricating an axle assembly can include: coupling a pair of bearing to opposite ends of a differential housing; placing the differential housing into a carrier housing assembly such that the bearings support the differential housing on the carrier housing assembly for rotation about a first axis; collecting a lubricant proximate a side of one of the bearings opposite the differential housing; and rotating the differential housing about the first axis to cause the one of the bearings to move a portion of the collected lubricant through the differential housing. A related axle assembly is also provided.

Abstract: An axle assembly that includes an axle housing assembly, a differential disposed in the axle housing assembly, an input pinion, a pair of axle shafts and a heat sink. The input pinion is coupled to the axle housing assembly and is configured to transmit a rotary input to the differential. The axle shafts are coupled to the differential and housed in the axle housing assembly. The heat sink is coupled to the axle housing assembly and is formed of a material having a thermal conductivity that is greater than that of the axle housing assembly. The heat sink does not consist entirely of a chrome plating, a zinc plating or a cadmium plating. A cover for an axle assembly is also provided.

Abstract: A shaft retention system is disclosed that is particularly useful for attaching an axle to a side gear in a differential case. The shaft preferably has an inner end with opposed flat surfaces that extend to a groove in the shaft. A spring washer and clip having mating flats are mounted on the inner end, with the flats on the spring washer and clip aligned with the flats on the shaft end. The clip is then rotated relative to the spring washer, and tabs on the spring washer snap into a notch in the clip preventing further rotation between the two. In this position, the flats on the clip no longer align with the flats on the inner end of the shaft preventing removal of the spring washer and clip from the shaft. The clip is preferably C-shaped, with the notch formed by the open end of the C.

Abstract: A speed sensing differential axle mechanism provides a plurality of teeth formed in a small diameter end portion of a differential case. In a preferred form, the teeth are integral to the case, spaced uniformly about the small diameter end portion thereof, and are disposed for relative rotation with respect to a stationary electronic pickup element secured rigidly in an associated external carrier. In the preferred embodiment, the pickup element is totally enclosed within the carrier, whereby it is protected from external environments, as well as from splash and spray oil circulating within the differential assembly. For the latter purpose, an internal baffle is utilized to protect the internal pickup element from the oil.