Abstract: A flow formed part includes a first end, a second end, and a side wall extending therebetween. A reinforcing member is disposed around the second end. The side wall has a profile formed along an inner surface of the side wall. The profile is adapted to be substantially burr free after windows are formed in the sidewall. A method of making a flow formed part includes the steps of disposing a preform on a tailstock, providing a plurality of rollers adjacent the tailstock, providing a mandrel having an outer surface including a plurality of alternating channels and protuberances, and causing the rollers to press the preform against the outer surface of the mandrel.

Abstract: A differential case assembly includes a differential case and a pinless gear assembly. The differential case has an open end and a side wall with an interior surface. The pinless gear assembly includes a retainer insert and a side gear with a shaft extending outwardly therefrom. The retainer insert is disposed adjacent the interior surface of the side wall. The retainer insert defines at least a portion of an aperture that receives an end of the shaft to align the gear assembly within the differential case.

Abstract: A flow formed part includes a first end, a second end, and a side wall extending therebetween. A reinforcing member is disposed around the second end. The side wall has a profile formed along an inner surface of the side wall. The profile is adapted to be substantially burr free after windows are formed in the sidewall. A method of making a flow formed part includes the steps of disposing a preform on a tailstock, providing a plurality of rollers adjacent the tailstock, providing a mandrel having an outer surface including a plurality of alternating channels and protuberances, and causing the rollers to press the preform against the outer surface of the mandrel.

Abstract: A flow formed part includes a first end, a second end, and a side wall extending therebetween. A reinforcing member is disposed around the second end. The side wall has a profile formed along an inner surface of the side wall. The profile is adapted to be substantially burr free after windows are formed in the sidewall. A method of making a flow formed part includes the steps of disposing a preform on a tailstock, providing a plurality of rollers adjacent the tailstock, providing a mandrel having an outer surface including a plurality of alternating channels and protuberances, and causing the rollers to press the preform against the outer surface of the mandrel.

Abstract: An apparatus includes a mandrel having a first end and a second end, the mandrel including a cavity formed therein, a pilot disposed in the cavity formed in the mandrel, a portion of the pilot extending outwardly from the first end of the mandrel, and an insert disposed in a channel formed in the mandrel and through an exterior surface of the mandrel, wherein a portion of the pilot abuts the insert and radial outward movement of the insert is caused by an axial movement of the pilot.

Abstract: A differential case assembly includes a differential case and a pinless gear assembly. The differential case has an open end and a side wall with an interior surface. The pinless gear assembly includes a retainer insert and a side gear with a shaft extending outwardly therefrom. The retainer insert is disposed adjacent the interior surface of the side wall. The retainer insert defines at least a portion of an aperture that receives an end of the shaft to align the gear assembly within the differential case.

Abstract: A differential case assembly includes a differential case and a pinless gear assembly. The differential case has an open end and a side wall with an interior surface. The pinless gear assembly includes a retainer insert and a side gear with a shaft extending outwardly therefrom. The retainer insert is disposed adjacent the interior surface of the side wall, The retainer insert defines at least a portion of an aperture that receives an end of the shaft to align the gear assembly within the differential case.

Abstract: A differential case assembly includes a differential case having an open end and a side wall with an interior surface. A plurality of major internal splines is formed on the interior surface of the side wall. The differential case assembly further includes a gear assembly with a retainer insert and a cross pin. The retainer insert is disposed adjacent the interior surface of the side wall between a pair of the major internal splines. The retainer insert has a hole formed therein. The cross pin has an end received in the hole of the retainer insert. The gear assembly is thereby aligned within the differential case.

Abstract: A flow formed part includes a first end, a second end, and a side wall extending therebetween. A reinforcing member is disposed around the second end. The side wall has a profile formed along an inner surface of the side wall. The profile is adapted to be substantially burr free after windows are formed in the sidewall. A method of making a flow formed part includes the steps of disposing a preform on a tailstock, providing a plurality of rollers adjacent the tailstock, providing a mandrel having an outer surface including a plurality of alternating channels and protuberances, and causing the rollers to press the preform against the outer surface of the mandrel.

Abstract: A differential case assembly includes a differential case and a pinless gear assembly. The differential case has an open end and a side wall with an interior surface. The pinless gear assembly includes a retainer insert and a side gear with a shaft extending outwardly therefrom. The retainer insert is disposed adjacent the interior surface of the side wall, The retainer insert defines at least a portion of an aperture that receives an end of the shaft to align the gear assembly within the differential case.

Abstract: A differential case assembly includes a differential case having an open end and a side wall with an interior surface. A plurality of major internal splines is formed on the interior surface of the side wall, The differential case assembly further includes a gear assembly with a retainer insert and a cross pin. The retainer insert is disposed adjacent the interior surface of the side wall between a pair of the major internal splines. The retainer insert has a hole formed therein. The cross pin has an end received in the hole of the retainer insert. The gear assembly is thereby aligned within the differential case.

Abstract: An apparatus includes a mandrel having a first end and a second end, the mandrel including a cavity formed therein, a pilot disposed in the cavity formed in the mandrel, a portion of the pilot extending outwardly from the first end of the mandrel, and an insert disposed in a channel formed in the mandrel and through an exterior surface of the mandrel, wherein a portion of the pilot abuts the insert and radial outward movement of the insert is caused by an axial movement of the pilot.