Abstract: A family of axle assemblies that employ a modular concept to maximize part commonality amongst the several axle assemblies. The axle assemblies have a housing assembly that employs a main housing that is formed from a casting that is common to all of the axle assemblies.

Abstract: A disconnecting axle includes a housing assembly including a first end cap coupled to a first side of a housing member to define a clutch cavity, and a second end cap coupled to a second side of the housing member to define a differential cavity. The housing member can define a central bore, a sump, and a plurality of passages. The central bore extends axially between the clutch and differential cavities. The sump can be spaced apart from the clutch and differential cavities, and the central bore. A clutch passage couples the clutch cavity to the sump. A differential passage couples the differential cavity to the sump. A first output member of the differential extends axially within the central bore. A piston is configured to compress friction plates to selectively transmit torque. A pump can pump fluid from the sump to the cylinder to move the piston.

Abstract: An axle assembly with a housing, a shaft received in the housing, a shaft bearing supporting the shaft for rotation relative to the housing about a shaft axis, a differential assembly, an annular band and a secondary retainer. The shaft bearing has an inner race, which is received on and directly engaged to the shaft, and an outer race that is received on and directly engaged to the axle housing. The differential assembly has an output member that is non-rotatably coupled to the shaft. The annular band is fixedly coupled to the shaft at a location along the axle shaft axis between the inner race and the output member. The secondary retainer is disposed along the axle shaft axis between the annular band and the output member and is configured to limit movement of the annular band along the axle shaft axis in a direction toward the output member.

Abstract: A vehicle with a primary driveline that is configured to distribute rotary power to a first set of vehicle wheels and a power transmitting device that can be selectively operated to transmit rotary power to a secondary driveline. The power transmitting device has an input member, which is driven by the primary driveline, and an output member that is selectively coupled to the input member to receive rotary power therefrom. The secondary driveline comprises a differential, a pair of shafts, and a side shaft coupling that selectively interrupts power transmission between the differential and one of the shafts.

Abstract: Mating bevel gears generally include a pinion gear having a body that rotates about an axis and a side gear having a body that rotates about an axis that intersects the axis of the pinion gear. Pinion gear teeth of the pinion gear have a side that defines a curvature with an involute section through which a pitch line extends and a parabolic shape between the pinion gear teeth. Side gear teeth of the side gear have a side that defines a curvature with an involute section through which a pitch line extends and a parabolic shape between the side gear teeth. The curvatures on the pinion and the side gear teeth cooperatively define a controlled relative radius of curvature section except where the involute sections are located. The controlled relative radius of curvature section defines a sum of values of radius of curvature at a point of contact between the curvatures of the pinion gear teeth and the side gear teeth. The sum has a constant or decreasing value.

Abstract: A power transmitting component that includes a housing, a case, a bearing, a bearing adjuster, and a retaining member. The housing defines a bearing bulkhead and an aperture, the aperture being disposed about a first axis. A pinion is coupled to the housing for rotation about a second axis that is not coincident with the first axis. A ring gear is coupled to the differential case and is meshed with the pinion. A bearing supports the case for rotation relative to the housing about the first axis. A bearing adjuster is disposed within the aperture and abuts the bearing. The retaining member is formed of a polymeric material and couples the bearing adjuster to the bearing bulkhead such that the bearing adjuster is non-rotatably and axially fixed to the housing and a preload is applied to the bearing in a direction along the first axis.

Abstract: An all-wheel drive vehicle driveline that includes a PTU input member, a spindle, a stub shaft, an axle shaft, a PTU clutch and a stub shaft clutch. The PTU input member, the spindle, the stub shaft and the axle shaft are rotatable about a first rotary axis. The axle shaft is received through the spindle. The PTU clutch is operable in a first PTU clutch mode, in which the PTU input member is rotatably coupled to the spindle, and a second PTU clutch mode in which the PTU input member is rotatably decoupled from the spindle. The stub shaft clutch is operable in a first stub shaft clutch mode, in which the stub shaft is rotatably coupled to the axle shaft, and a second stub shaft clutch mode, in which the stub shaft is rotatably de-coupled from the axle shaft.

Abstract: A disconnecting power take-off unit having a housing, an input shaft, a gear shaft, a seal journal and a dynamic seal. The input shaft is rotatably disposed in the housing and includes a plurality of splines or teeth. The gear shaft is disposed about the input shaft and is supported on an end by a gear shaft bearing having an inner bearing race. The seal journal is received over the splines or teeth and is fixedly and sealingly engaged to the input shaft. The seal journal has an exterior seal surface that can be sized larger in diameter than the splines or teeth on the input shaft and/or the inside diameter of the inner bearing race of the gear shaft bearing. The dynamic seal is received over the spline teeth and is sealingly engaged to the housing and the exterior seal surface.

Abstract: The present teachings provide for a power transfer device and method of forming a power transfer device that includes a unitarily formed transfer member and a support member. The transfer member can be supported within a housing for rotation about an input member and can be coupled to the input member to receive rotational power therefrom. A ring gear defined by the transfer member can meshingly engage with a pinion gear. The support member can be disposed concentrically about the input member and be rotatable about a first axis relative to the housing. The support member can have a first end and a second end. The first end of the support member can be supported for rotation relative to the housing by a support bearing. The second end of the support member can be received within a bore defined by the transfer member and fixedly coupled thereto for common rotation.

Abstract: A vehicle driveline having a torque transfer device and a fluid circuit for operating the torque transfer device. The fluid circuit has a motor, a pump driven by the motor, an actuator, and a pair of valves. The valves are arranged in the fluid circuit to control fluid circulation within the fluid circuit and can be operated such that fluid pressure in the actuator can be maintained (i.e., to maintain engagement of the torque transfer device) without operating the pump.

Abstract: A torque transfer device can include a housing and a clutch. The housing can define a clutch cavity and a pocket. The pocket can be formed at an axial end of the clutch cavity and have a generally arcuate shape that extends circumferentially about the clutch cavity above a static lubrication level. The clutch can include an outer carrier, an inner carrier, a plurality of first and second interleaved friction plates. One of an outer and an inner plate carrier of the clutch can be coupled to an input member for common rotation. The other of the carriers can be coupled to a differential case for common rotation. Rotation of the outer carrier relative to the housing through a fluid in the clutch cavity can sling a portion of the fluid toward an inner surface of the housing to cause the portion of the fluid to collect in the pocket.

Abstract: An all-wheel drive vehicle driveline can include an input member, differential, pump, first clutch, valve, and second clutch. The differential can include a case member, differential gearset, first output, and second output. The differential gearset can receive input torque from the case member and output differential torque to the first and second outputs. The pump can pump a fluid to a first conduit. The first clutch can transmit torque between the input and case members when a pressure in the first conduit exceeds a first predetermined pressure. The valve can couple the first conduit to a second conduit. The second clutch can couple the case member to the first output for common rotation when a pressure in the second conduit exceeds a second predetermined pressure. The valve can selectively permit fluid communication from the first conduit to the second conduit.

Abstract: An axle assembly can include a housing defining a reservoir and cylindrical bore open thereto. A clutch can selectively transmit torque between input and output members. A first inlet/outlet of a pump can be in fluid communication with the reservoir and define first threads coaxial with the cylindrical bore. The pump can be configured to pump fluid from the first inlet/outlet to an actuator of the clutch via a second inlet/outlet. The filter can include a base, port, and filter element. The port can define second threads that threadably engage the first threads. The base can be fixedly coupled to the port and include a cylindrical wall coaxial with the second threads. A seal member can form a seal between the cylindrical wall and the cylindrical bore when the first and second threads are engaged. The filter element can be disposed between the reservoir and the first inlet/outlet.

Abstract: A power transmitting component having a actuator with a lead screw, which is driven by a motor and a transmission, a pusher assembly driven by the lead screw, and a clutch fork. Translation of the pusher coordinates movement of the clutch fork along its axis.

Abstract: An axle assembly that includes a housing assembly, an input pinion, a ring gear, a ring gear bearing, and a differential assembly having a differential case. The ring gear bearing supports the ring gear for rotation on the housing assembly as well as handles thrust loads between the ring gear and the housing assembly in opposite axial directions. The ring gear bearing includes an outer bearing race having a first race member, which may be unitarily and integrally formed with the ring gear, and a second race member that is received in a groove formed on the ring gear. The differential case is coupled to the ring gear and secures the second race member to the ring gear.

Abstract: A differential assembly can include a case, a first side gear, a second side gear, a first pinion gear, a second pinion gear, a third pinion gear, and a cross-pin assembly. The case can be adapted to be supported for rotation about an output axis. The first and second side gears can be disposed within the case and rotatable about the output axis relative to the case. The first, second, and third pinion gears can be disposed within the case and meshingly engaged with the first and second side gears. The cross-pin assembly can include a spider, first, second, and third pins. The proximal end of the first pin can define a first bore that can receive a post of the spider to couple the first pin to the spider. Each pinion gear can be supported by one of the pins for rotation relative to the case.

Abstract: A G-rotor pump assembly is disclosed. The assembly makes use of a housing having a pump/motor housing portion and a laterally projecting housing portion. An electric motor is disposed within the pump/motor housing portion. A controller has a circuit board with a portion which is positioned within the pump/motor housing portion so as to be generally axially aligned with the electric motor and in proximity to the electric motor. A lower cover is configured to engage with the housing to encapsulate the controller and the electric motor within the housing.

Abstract: A damped propshaft assembly with a hollow shaft and a tuned damper, which is received in the hollow shaft and includes a liner and a damping member. The liner's mass and stiffness are tuned to attenuate one or more of a bending mode vibration and a torsion mode vibration that occurs at a first predetermined frequency. The liner is not configured to substantially damp shell mode vibration that occurs at a frequency that is not equal to the first predetermined frequency. The damping member is coupled to the liner and is configured to primarily attenuate shell mode vibration in the hollow shaft at one or more desired frequencies. The tuned damper attenuates the at least one of the bending moment vibration and the torsion mode vibration at the first predetermined frequency and also attenuates shell mode vibration. A method for forming a damped propshaft assembly is also provided.

Abstract: The present teachings provide for a clutched component including a first member, a second member, and a clutch. The first member can have an output portion. The second member can have an input portion that is disposed within the output portion. The clutch can include a plurality of first lock members and a control member for coordinating radially inward movement of the first lock members to drivingly couple the output portion and the input portion.

Abstract: A differential includes a cross-pin assembly. The case can rotate about an output axis. First and second side gears can be rotatable about the output axis relative to the case. First, second, and third pinion gears can be meshingly engaged with the first and second side gears. The cross-pin assembly can include first, second, and third pin members, each having a cylindrical body and a finger fixedly coupled to a proximal end of the corresponding cylindrical body. The first, second, and third pinion gears can be rotatably disposed about the corresponding first, second, or third cylindrical body. The first, second, and third fingers can overlap along the output axis to non-rotatably couple the first, second, and third pin members together.