Abstract: A lubrication system for a transfer case includes a pump in fluid communication with a lubricant source and a power transfer assembly, as well as one or more valves positioned along fluid flow paths between the lubricant source and the power transfer assembly. The valves may allow full fluid flow or may restrict fluid flow to various components of the transfer case as conditions warrant. A fluid guide insert may be used to help direct lubricant flow to the components.

Abstract: An actuator for a transfer case includes an actuator member, a face cam mechanism, and a motor. The actuator member includes a circumferential flange and an annular body extending from an inner periphery of the circumferential flange. The annular body includes a circumferential slot opposite the flange defined between two end walls formed by the annular body. One of the end walls includes a bearing member coupled thereto. The face cam mechanism includes a follower coupled to a cam member. The cam member is configured to displace axially when rotated. The follower is disposed within the slot. In a first range of motion, the annular member is rotated independent of the face cam mechanism. In a second range of motion, the bearing member engages the follower to rotate the second cam member relative to the first cam member, and the follower moves axially along the bearing member.

Abstract: A lubrication system for a transfer case includes a pump in fluid communication with a lubricant source and a power transfer assembly, as well as one or more valves positioned along fluid flow paths between the lubricant source and the power transfer assembly. The valves may allow full fluid flow or may restrict fluid flow to various components of the transfer case as conditions warrant. A fluid guide insert may be used to help direct lubricant flow to the components.

Abstract: A transfer case includes an input shaft, a primary output shaft, a secondary output shaft, and an actuator. The primary output shaft is coupled to the input shaft with a gear reduction mechanism. The secondary output shaft is selectively coupleable to the primary output shaft with a secondary torque transfer mechanism. The actuator includes a first actuation mechanism, a second actuation mechanism, and a driver gear assembly. The first actuation mechanism is configured to operate the gear reduction mechanism. The second actuation mechanism is configured to operate the secondary torque transfer mechanism. The drive gear assembly includes a gear plate member, a sense plate member configured to engage the first actuation mechanism, and a hub member configured to engage the second actuation. The sense plate member and the hub member are independently coupled to the gear plate member to rotate in unison with the gear plate member.

Abstract: A transfer case includes an input shaft, a primary output shaft, a secondary output shaft, and an actuator. The primary output shaft is coupled to the input shaft with a gear reduction mechanism. The secondary output shaft is selectively coupleable to the primary output shaft with a secondary torque transfer mechanism. The actuator includes a first actuation mechanism, a second actuation mechanism, and a driver gear assembly. The first actuation mechanism is configured to operate the gear reduction mechanism. The second actuation mechanism is configured to operate the secondary torque transfer mechanism. The drive gear assembly includes a gear plate member, a sense plate member configured to engage the first actuation mechanism, and a hub member configured to engage the second actuation. The sense plate member and the hub member are independently coupled to the gear plate member to rotate in unison with the gear plate member.

Abstract: An actuator for a transfer case includes an actuator member, a face cam mechanism, and a motor. The actuator member includes a circumferential flange and an annular body extending from an inner periphery of the circumferential flange. The annular body includes a circumferential slot opposite the flange defined between two end walls formed by the annular body. One of the end walls includes a bearing member coupled thereto. The face cam mechanism includes a follower coupled to a cam member. The cam member is configured to displace axially when rotated. The follower is disposed within the slot. In a first range of motion, the annular member is rotated independent of the face cam mechanism. In a second range of motion, the bearing member engages the follower to rotate the second cam member relative to the first cam member, and the follower moves axially along the bearing member.