Abstract: A method and apparatus for filling a hydraulic control apparatus of the type including a reservoir, a diaphragm positioned in the reservoir, a master cylinder, a slave cylinder, and a conduit interconnecting the master cylinder and the slave cylinder. The apparatus is filled by the use of a filling head which is fitted into the open top of the reservoir and which includes a nozzle portion having an exterior surface enclosing a volume which approximates the volume of the diaphragm so that, following filling of the apparatus, removal of the filling head, and reinsertion of the diaphragm, the apparatus is automatically placed in a totally filled condition.

Abstract: An automatic adjusting device for a twin-plate clutch includes a pin (139) which is mounted in a bore (137) formed in an intermediate pressure plate (135) of the clutch so as to be slidable along an axis parallel to the axis of rotation of the clutch. First and second abutments are provided adjacent to the pin, the first abutment providing a stop for determining adjustment of the pin relative to the intermediate pressure plate and the second abutment providing a stop for determining an intermediate position of the intermediate pressure plate. A plate (144) is mounted on the pin by way of an aperture provided in the plate, the aperture being dimensioned such that the plate is tiltable relative to the pin. A third abutment (145) is provided on the intermediate pressure plate and is engageable with the tiltable plate, the third abutment defining an axis about which the plate is tiltable.

Abstract: A method of forming a hydraulic cylinder assembly utilizing a plastic material for the cylinder body. The method includes forming the cylinder body in a first molding operation and simultaneously molding one or more external walls on the exterior of the cylinder body having an axial thickness less than the axial thickness of the walls of the cylinder body and thereafter increasing the axial thickness of the exterior walls to a value substantially exceeding the thickness of the cylinder walls so as to define an appendage. Where the appendage includes a mounting flange, a small external annular wall is molded on the cylinder body during the initial molding operation having an axial thickness less than the thickness of the walls of the cylinder body and a larger flange is thereafter formed around the small flange.

Abstract: A concentric hydraulic actuator for use with a manual transmission motor vehicle of the type in which the actuator housing moves in response to depression of the clutch pedal and the associated piston remains axially affixed.

Abstract: A control assembly for a motor vehicle including a bracket; a hydraulic cylinder assembly including a cylinder mounted on the bracket and a piston rod projecting out of the cylinder; and a pedal assembly including a pedal arm mounted for pivotal movement on the bracket about a pivot axis and pivotally connected to the free end of the piston rod at a location spaced from the pivot axis. A sleeve is mounted on the bracket and is journaled on a pivot shaft secured to a fixed structure of the vehicle so that the entire assembly, including the bracket, hydraulic cylinder, and pedal assembly, may be pivotally adjusted within the passenger compartment of the motor vehicle. A slot in the bracket spaced from the pivot axis coacts with a fastener carried by the vehicle fixed structure to secure the assembly in any position of pivotal adjustment within the passenger compartment.

Abstract: A hydraulic cylinder having an internal groove in which is disposed a seal member peripherally engaging a seal-less reciprocable piston. In one form, the hydraulic cylinder is a master cylinder having a valved port in fluid communication with a source of fluid, opening and closing of the port being effected by a reciprocable plunger mounted on the end of the piston. An outlet port and a conduit places the chamber of the master cylinder in fluid communication with the chamber of the slave cylinder. In a slave cylinder version, a single port places the pressure chamber of the slave cylinder in communication with the master cylinder for introducing fluid and withdrawing fluid into and from the slave cylinder chamber, and thereby reciprocating the slave cylinder piston.

Abstract: A hydraulic control apparatus, having a master cylinder, a slave cylinder and a conduit connecting the master cylinder to the slave cylinder, is made of separate modular units interconnectable by leakproof connectors. The apparatus is prefilled with hydraulic fluid while the separate modular units are interconnected, and after filling the separate modular units are disconnected and shipped to a user, unconnected but filled with hydraulic fluid. Alternatively, the separate modular units may be individually filled with hydraulic fluid, and shipped to a user unconnected but each filled with hydraulic fluid. After installation on a utilization device, for example a motor vehicle, the complementary connector members are reconnected for placing the individual modular units in hydraulic fluid communication. The connectors take the form of complementary members which are arranged to open fluid passageway during connection.

Abstract: An electric actuator for use in engaging and disengaging the clutch of a manual transmission motor vehicle. The actuator comprises an electric motor which is sized to be positioned within the housing of the clutch. The motor includes an annular armature assembly which is positioned concentrically around the clutch shaft and which drives a nut member which in turn drives a screw member to move the release bearing linearly to engage and disengage the clutch. In one embodiment, the nut and screw comprise an acme thread arrangement and in another embodiment the nut and screw are of the ball type. In one embodiment the screw advances linearly in response to rotation of the armature assembly and in another embodiment the housing and armature assembly advance linearly in response to rotation of the armature assembly while the screw remains fixed.

Abstract: A master cylinder assembly especially adapted for mounting in the passenger compartment of a motor vehicle in association with the clutch pedal assembly of the motor vehicle. The unit is permanently sealed and is non-serviceable so that no fluid leakage occurs in the passenger compartment as a result of attempts to service the unit. The master cylinder assembly includes a cylinder having an open rearward end and a closed forward end, an external mounting flange intermediate the ends, and an elongated reservoir mounted in piggyback fashion on the cylinder between the mounting flange and the forward end of the cylinder with the rear end of the reservoir pivotally secured to the mounting flange and with a discharge fitting on the forward end of the reservoir moving into telescopic sealing relation with a reservoir fitting on the forward end of the cylinder in response to pivotal movement of the rear end of the cylinder about the pivot axis defined between the rear end of the reservoir and the mounting flange.

Abstract: An electrically driven master cylinder assembly and various vehicle control systems utilizing the master cylinder assembly. Several forms of master cylinder assemblies are disclosed. In the preferred form, the assembly includes an electric DC motor directly coupled to a master cylinder unit with the central axis of the motor coaxial with the central axis of the bore of the master cylinder, a ball nut is positioned within the housing of the electric motor for rotation with the armature of the motor, and a ball screw is positioned on the axis of the motor and is driven linearly in response to rotation of the armature.

Abstract: A brake failure warning system for a dual hydraulic master cylinder for use with a motor vehicle. The warning system employs a pair of Hall Effect magnetic sensors which are positioned on the exterior of a plastic cylinder in association with the two pistons mounted within the bore of the cylinder. The pistons have ferrous frustoconical portions which coact with the respective sensors to generate position signals that vary as the pistons move in the bore past the respective sensors. The two position signals are fed to a logic board which compares the signals and generates an error or warning signal in the event that the difference between the two signals exceeds a predetermined amount indicative of failure of one of the two braking systems of the vehicle.

Abstract: A hydraulic clutch actuator for a motor vehicle of the concentric type in which the actuator is mounted concentrically around the transmission input shaft of the vehicle within the housing of the clutch. The actuator includes a housing structure defining a central quill shaft surrounding the input shaft of the vehicle and slidably supporting the hub portion of the bearing carrier and further defines an annular piston bore spaced radially outwardly from the quill shaft to define an annular bore between the piston bore and the quill shaft into which the rear end of the hub portion of the bearing carrier may move during the operation of the actuator so as to provide overlap as between the annular piston and the bearing carrier and minimize the axial dimension of the actuator. The preload spring is also positioned in the annular bore between the quill shaft and the piston bore so as to further optimize the compact packaging of the actuator.

Abstract: A method of assembling a motor vehicle in which a multicontact switch is provided on the input rod of the master cylinder of a prefilled master and slave cylinder hydraulic apparatus; the master cylinder is positioned in the engine compartment of a vehicle and the input rod, with the switch mounted thereon, is passed from the engine compartment through an aperture in the firewall of the vehicle to position the input rod and switch in the passenger compartment of the vehicle and position the master cylinder housing adjacent the fire wall; the master cylinder is secured to the fire wall; and the plug of a wiring harness including several electrical vehicle circuits is plugged into a multiple contact outlet socket on the switch so as to provide a plurality of electrical control systems for the vehicle respectively controlled by the contacts of the switch. For example, the switch contacts may control a cruise control disconnect circuit, an electronic fuel injection circuit, and an ignition interlock circuit.

Abstract: A hydraulic master cylinder formed by telescopically fastening together a pair of cylinder housings to form a cylinder. A piston in the cylinder is operative to transfer hydraulic fluid to a slave cylinder connected to the master cylinder. The pressure or power stroke of the piston is effected by exerting a pull on the piston by a pull cable attached to one side of the piston. A body, attached to one of the cylinder housing, provides a reservoir for hydraulic fluids. A cap on the reservoir closes a fluid filling opening. Expansion bellows in the reservoir accommodates changes in the fluid level in the reservoir as the piston is being reciprocated. The bellows is connected to the cap so as to be removed as a unit with the cap when the reservoir is being filled.

Abstract: A hydraulic master cylinder assembly of the type including a reservoir in which a diaphragm is disposed to divide the reservoir chamber into a hydraulic fluid chamber outside of the diaphragm and in communication with the pressure chamber of the master cylinder and a gas chamber within the diaphragm. The diaphragm is generally tubular with an open end and a closed end, and in a cross section transverse to the central axis of the diaphragm, includes a plurality of radially extending arms arranged about the central axis of the diaphragm and each including a pair of side walls defining therebetween a portion of the volume of the gas chamber. The diaphragm is movable between an expanded condition in which it assumes a substantially circular configuration in cross section and a collapsed condition in which each of the pairs of side walls of the arms are collapsed with respect to each other to reduce the volume of the chamber.

Abstract: A throttle control system including position sensing means to track the instantaneous position of the accelerator pedal, position sensing means to track the instantaneous position of the throttle valve, and a control module operative to compare the accelerator pedal and throttle valve position signals and generate a control signal for delivery to an actuator to position the throttle valve in response to the position called for by the accelerator pedal.

Abstract: An electrical switch operated by the input member of a hydraulic master cylinder and controlling the stop signal lights of a motor vehicle, when associated with the master cylinder of a hydraulic brake system, and/or controlling a cruise control disconnect circuit. When associated with the master cylinder of a clutch hydraulic control system, the switch is adapted to close an interlock circuit allowing the motor vehicle driver to start the engine only when the clutch is fully released, and to operate a cruise control disconnect circuit upon small displacement of the input member from its home position.

Abstract: The structure comprises a molded plastics housing either having a metallic sleeve molded therein which forms a cylinder for a piston or defining the cylinder itself. An annular retainer for the piston is provided which abuts a location surface of the sleeve or an anchoring element molded in the housing. The location surface is provided by deforming the sleeve or anchoring element so that the location surface engages the annular retainer at a position radially inboard of its outer periphery.

Abstract: The clutch release mechanism includes a fluid actuator having an actuator member movable by fluid pressure in a clutch release direction to release the clutch, a release bearing assembly for connection to part of the clutch, and a coupling for connecting the release bearing assembly to the actuator member. The coupling is fluid operable whereby in one condition it prevents axial separation of the actuator member and release bearing assembly by engagement of pins and a groove and, in another condition, it allows axial separation and coupling of the release bearing assembly and the actuator member by disengagement of the pins and groove.

Abstract: A transmission comprises gear trains which provide increasing speed ratios and two clutches which are operable independently to provide alternative paths through the gear trains between an input and an output. The gear trains provide alternate ratios driven respectively through one and the other clutch. The input comprises a first shaft drivable by one clutch and a shaft drivable by the other clutch. A layshaft is provided through which drive in a selected ratio is transmitted from one of the first and second shafts to the other to drive the output which is also a shaft. One of the first and second shafts has a gear thereon which meshes with a gear on the output shaft.