Abstract: A method of manufacturing an irregularly shaped forging includes heating a billet to a predetermined temperature, placing the heated billet within the cavity of a die, advancing a punch into the cavity to begin to disperse the material into a plurality of radially extending extremities of the cavity and continuing to advance the punch into the die to force a portion of the material to enter predetermined clearance zones between the punch and the die to form an irregularly shaped forging having a plurality of axially extending flash portions.

Abstract: An axle assembly that includes a differential casing, which is rotatable about an axis, a pair of side gears that are disposed within the differential casing, a spacer and a cross pin. The spacer is disposed between the side gears. The cross pin is fixed to the differential casing and extends through the spacer. The cross pin is employed to limit end play of the axle shafts in a direction toward one another. The aperture in the spacer that receives the cross pin is relatively larger than the cross pin so that the spacer can control end play of the side gears independently of the cross pin.

Abstract: An exciter ring assembly to detect rotational parameters of an axle within a tube has an exciter ring attached to the axle by an elastomer insert. The insert provides a frictional interference fit with the axle. The insert affixes the exciter ring to rotate with the axle. The elastomer insert is supplied with radially-spaced axial channels to enable oil flow past the assembly. The outer member of the assembly is press fit into the axle tube. The outer member remains stationary with respect to the axle tube. The outer member restricts the axial movement of the exciter ring and enables rotation of the exciter ring and provides oil flow across the exciter ring assembly.

Abstract: A power transfer device includes an input, a gear set for transferring power from the input to at least one output, a housing and a cover. The housing includes an access aperture sized for receiving the gear set. The access aperture includes a threaded wall. The cover closes the aperture and is threadably engaged with the threaded wall to secure the cover to the housing.

Abstract: A differential assembly includes a differential housing defining a chamber and a pair of aligned openings communicating with the chamber. A pair of output shafts extend through the openings in the differential housing and include end segments located within the chamber. A pair of side gears are positioned within the chamber and fixed to the end segments of the output shaft. Paired sets of pinions are rotatably mounted within the differential housing and placed in meshed engagement with each other and with one of the side gears. A retention assembly interconnects the end segments and includes a spacer having a web positioned between and walls partially encompassing the end segments. The retention assembly includes a ring surrounding the spacer to selectively retain and allow removal of clips engaged with the end segments.

Abstract: A power transmitting device including a housing having an input shaft, at least one output shaft and a gear set positioned in the housing. The gear set transmits rotary power between the input shaft and the output shaft. An electrical actuator includes a linearly moveable member and is operable to drivingly engage the moveable member with the gear set. A sensor is positioned within the housing and operable to output a signal indicative of the linear position of the moveable member.

Abstract: A two speed drive system for an all wheel drive vehicle includes a double planetary gear front differential and a power take-off unit transferring drive torque to a front wheel set and a rear wheel set of the vehicle. A rear differential connects the power take-off unit and the rear wheel set providing the drive torque to the rear wheel set. A two speed drive unit is positioned between the power take-off unit and the rear differential. The drive unit shifts between a high range drive operation and a low range drive operation. The drive unit may be mounted directly to either the power take-off unit or the rear differential.

Abstract: A vehicle axle assembly having an axle housing, an axle shaft and a sensor. The axle housing has a tubular portion. A flat is formed on an annular wall of the tubular portion proximate a distal end of the tubular portion. A hole, which intersects the flat, is formed through the tubular portion. The axle shaft can have an integrally formed target portion that includes a plurality of teeth. The sensor is mounted in the hole and abuts the flat to space a tip of the sensor apart from the teeth of the target portion by a predetermined distance.

Abstract: A universal joint includes a yoke connected to a cruciform by bearing cup assembly. The bearing cup assembly includes a bearing cup, a bearing and an integral seal deflector retainer. The bearing cup assembly is rotatably coupled to a trunnion of the cruciform. The integral seal deflector retainer includes a case engaging the cruciform to retain the bearing assembly on the trunnion.

Abstract: A differential assembly includes a case, a pair of pinion gears, a pair of side gears and an electrically operable coupling including an electromagnet. The coupling selectively drivingly interconnects one of the side gears and the case. The electromagnet of the coupling is axially moveable within the case to selectively place the differential assembly in an open or a locked condition.

Abstract: The present invention provides for bevel gears having a localized and stable bearing contact. The localization of bearing contact is achieved by substitution of flat tooth surfaces with parabolic tooth surfaces. This is accomplished by either modifying line-contact directly or by using a generating parabolic cylinder during generation of the tooth surfaces. The actual contact area is spread over an ellipse centered around an instantaneous theoretical point of contact at the apex of the parabolic tooth surface. This localized bearing contact reduces the shift of the bearing due to assembly and manufacturing errors, thereby providing a more durable and quieter gear. Furthermore, the geometry of the gear enables creation of dies from which the gear may be forged. Transmission errors are modeled using a pre-designed parabolic function that coincides with the parabolic tooth surface design of the present invention.

Abstract: A universal joint for interconnecting a pair of rotating shafts includes a pair of bifurcated yokes interconnected by a cruciform. The cruciform includes four orthogonal trunnions each including a lubricant passage. A thrust washer engages an inner surface of the lubricant passage to retain a bearing assembly on each trunnion.

Abstract: An axle assembly including a differential gear set having a ring gear. The axle assembly includes a carrier assembly housing that contains the differential gear set and an arcuate fence disposed adjacent to the ring gear that connects to the carrier assembly housing. A moveable plate slidingly connects to the arcuate fence. The moveable plate has an open position, a closed position and a plurality of positions therebetween. The closed position is closer to the ring gear than the open position. The arcuate fence and/or the moveable plate may reduce churning of the lubrication to increase the cooling efficacy of the lubrication.

Abstract: An axle assembly with a cooling pump. The cooling pump includes a disk-shaped wheel with a plurality of radially-spaced ducts formed therein. The wheel is positioned in proximity to the axle assembly and rotated, allowing the ducts to draw air therethrough and direct the air to the axle assembly.

Abstract: An axle assembly includes an axle housing having a main body and defining an internal cavity. The axle housing includes a first and second opening defined in the main body and adapted to support a first and second differential bearing respectively. A differential assembly is supported in the axle housing with the first and second differential bearings. The main body defines an inner mounting surface, an outer face and an inner circumferential surface extending between the inner mounting surface and the outer face. The inner circumferential surface defines a third opening. The main body defines a relief formed through the inner mounting surface and extending through a portion of the inner circumferential surface. The relief defines a fluid communication path for delivering fluid to a pinion bearing assembly arranged in the third opening.

Abstract: A differential assembly includes a case, a pair of pinion gears, a pair of side gears and an electrically operable coupling including an electromagnet. The coupling selectively drivingly interconnects one of the side gears and the case. The electromagnet of the coupling is axially moveable within the case to selectively place the differential assembly in an open or a locked condition.

Abstract: A method of manufacturing an irregularly shaped forging includes heating a billet to a predetermined temperature, placing the heated billet within the cavity of a die, advancing a punch into the cavity to begin to disperse the material into a plurality of radially extending extremities of the cavity and continuing to advance the punch into the die to force a portion of the material to enter predetermined clearance zones between the punch and the die to form an irregularly shaped forging having a plurality of axially extending flash portions.

Abstract: A power transmission device includes a housing, a differential assembly having a case and a bearing assembly rotatably supporting the case within the housing. A preload is applied to the bearing assembly along a load path. A shim is positioned in the load path with the bearing assembly. The shim is constructed at least in part from a material having a predetermined coefficient of thermal expansion such that the shim is operable to compensate for different rates of thermal expansion in the components within the load path to maintain a desired bearing preload or a range of operating temperatures.

Abstract: An axle assembly for a motor vehicle. The assembly comprises a carrier housing and a differentially assembly rotatably mounted to the carrier housing. A ring gear is fixed to the differential assembly. A first pinion is in meshing engagement with the ring gear. The first pinion is driven by a combustion engine and is operable to drive the ring gear. An electric drive assembly is mounted to the carrier housing. The electric drive assembly comprises an electric motor and a second pinion. The second pinion is in meshing engagement with the ring gear. The second pinion is driven by the electric motor and is operable to drive the ring gear.

Abstract: A method for fabricating an input pinion for an automotive differential that includes: providing a shaft; forging a pinion with a plurality of teeth such that each tooth is formed to at least a near-net size, forming a hole in the pinion, pressing an end of the shaft into the hole in the pinion, and securing the shaft to the pinion.