Abstract: A transfer case for use in a four-wheel drive vehicle and having a clutch assembly disposed on a front output and a pass-through rear output arrangement. The front output is a front output shall. The rear output is established by directly interconnecting a transmission output shaft to an end segment of a rear propshaft. A transfer assembly is driven by the transmission output shaft and can be selectively coupled to the front output shaft via the clutch assembly.

Abstract: A two-speed transfer case for a four-wheel drive vehicle is provided. The transfer case has a two-speed gear reduction unit, a range clutch, and a range shift mechanism. The range shift mechanism is operably disposed between an input shaft and a rear output shaft and includes a range cam defining a guide slot having a unique profile for converting rotation thereof into linear movement of the range clutch. The guide slot includes low-range dwell segment and a high-range dwell segment interconnected by a range shift segment. The range shift segment defines a plurality of interconnected cam portions, wherein each cam portion is associated with a different load required to move the range clutch between a high-range and low-range position. The transfer case further includes a mode shift mechanism for establishing a high-range drive connection and a low-range drive connection associated with the dwells of the range cam.

Abstract: A two-speed active transfer case includes an input shaft adapted to receive drive torque from a powertrain, a rear output shaft adapted for connection to a rear driveline and aligned with the input shaft for rotation about a first rotary axis, a front output shaft adapted for connection to a front driveline and aligned for rotation about a second rotary axis, and a transfer mechanism driven by the rear output shaft. The transfer case also includes a two-speed range mechanism operably disposed between the input shaft and the rear output shaft, a range shift mechanism for controlling operation of the two-speed range mechanism, a mode mechanism operably disposed between the transfer mechanism and the front output shaft, and a mode shift mechanism for controlling operation of the mode mechanism.

Abstract: An active transfer case is disclosed having a multi-plate friction clutch installed on the front output shaft. A splash recovery lubrication system is provided to capture lubricant splashed from the sump in response to rotation of the friction clutch and transfer the captured lubricant to a central clutch feed chamber to cool and lubricate the components of the friction clutch.

Abstract: A two-speed transfer case configured for use in heavy-duty four-wheel drive vehicles and which is equipped with a low-torque power transfer arrangement and a high-torque power transfer arrangement.

Abstract: An integrated pinion/bearing/coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles having mounting features and venting features. The integrated PBC assembly includes a hollow pinion unit made of steel and including a pinion shaft segment and a pinion gear segment, and a coupling unit having a hub segment made of aluminum. A brazing sleeve is used to braze the aluminum hub segment of the coupling unit to the steel pinion shaft segment of the pinion unit.

Abstract: A transfer case for a four-wheel drive vehicle having a disconnectable secondary axle assembly. The transfer case is configured to include a pumpless lubrication sump maintained in relation to a mainshaft for lubricating rotary components surrounding the mainshaft.

Abstract: A venting arrangement for use with power transfer assemblies of the type used in motor vehicle driveline and drivetrain applications includes a vent oil deflector assembly. The vent oil deflector assembly is associated with an inside wall within an enclosed chamber and is configured to deflect lubricating oil splashed within the chamber away from an air venting passageway. The deflection feature and the venting feature are integrated into a common assembly.

Abstract: An integrated pinion shaft and constant velocity joint (PS/CVJ) assembly for use in motor vehicle driveline applications to transfer torque between a propshaft and a ring gear. The PS/CVJ assembly includes a pinion shaft having a pinion gear segment meshed with the ring gear and a hollow pinion shaft segment. The PS/CVJ assembly also includes a constant velocity joint having an inner race coupled to the propshaft and an outer race integral with or fixed to an end portion of the pinion shaft segment.

Abstract: A transfer case for a four-wheel drive motor vehicle includes a two-speed range clutch unit, a mode clutch unit, a power-operated actuation mechanism and a control system. The actuation mechanism includes an electric motor, a geartrain driven by the motor for controlling rotation of an actuator shaft, a range actuator assembly and a mode actuator assembly. The range actuator assembly functions to move a shift collar associated with the range unit in response to rotation of the actuator shaft. The mode actuator assembly includes a mode cam and a ballramp unit. The mode cam is rotatively driven by the actuator shaft for controlling the clutch engagement force exerted on the friction clutch by the ballramp unit. The control system controls movement of the shift collar during motive operation of the motor vehicle to permit on-the-move range shifting.

Abstract: A torque transfer mechanism for a vehicle, including a housing and a pump disposed therein. The housing includes an exterior surface, an interior surface, and an interior compartment. The interior surface of the housing includes at least one pocket formed therein with the at least one pocket having a plurality of pocket surfaces, which define an interior area. The pump includes a pump portion and a pump housing. The pump housing includes at least one projecting tab extending outwardly therefrom. The at least one projecting tab disposed within the at least one pocket to secure the pump within the transfer case housing. The at least one projecting tab has a pump crown disposed thereover, with the pump crown engaging each of the plurality of pocket surfaces and substantially filling out the interior area.

Abstract: An integrated pinion, bearing and coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles. The PBC assembly includes a pinion unit having a pinion gear segment and a pinion stub shaft segment, and a coupler unit having a coupling flange segment and a coupler shaft segment. The pinion stub shaft segment surrounds and is in press fit engagement with the coupler shaft segment. A portion of the coupler shaft segment is deformed to be retained within one of a receiver groove and raised projections formed in the pinion stub shaft segment so as to fixedly secure the coupler unit to the pinion unit.

Abstract: A clutch module which includes a first rotating member including at least one strut actuation module and a second engaged member including cam surfaces thereon for engagement by said strut actuation module. The strut actuation module includes a frame with a strut pivotally movable with respect to the frame. The strut includes an engagement end and a base end including a first side and a second side thereof. A pin or post portion extends from the frame and has an insulated bobbin with an energizable coil surrounding the bobbin. A U-shaped member including a pair of actuation legs is attached to the pin member and forms a magnetic gap between the base end of the strut and peripheral ends of the legs, such that when the coil is energized the peripheral ends of the legs are polarized in a first polarity and the frame and the strut are polarized with an opposite polarity thereby biasing the strut toward the peripheral ends and pivoting the actuation end into engagement with a cam surface of the engagement member.

Abstract: A torque transfer mechanism is provided for controlling the magnitude of a clutch engagement force exerted on a multi-plate clutch assembly that is operably disposed between a first rotary and a second rotary member. The torque transfer mechanism includes a power-operated clutch actuator for generating and applying a clutch engagement force on the clutch assembly. Clutch actuator assembly includes a clutch apply operator for controlling the magnitude of a clutch engagement force applied to the clutch assembly. The clutch operator includes a first and second cam plate that are spaced form in one another to define a cavity therebetween. A sealing element extends between the first and second cam plates to seal the cavity between the first and second cam plates for retaining fluids in the cavity.

Abstract: A two-speed active transfer case is disclosed having a range shift mechanism with a moveable range shift component and a contactless position sensing arrangement for detecting the position of said moveable range shift component.

Abstract: An active transfer case is disclosed having a multi-plate friction clutch installed on the front output shaft. A splash recovery clutch lubrication system is provided to capture lubricant splashed from the sump in response to rotation of the friction clutch and transfer the captured lubricant to a central clutch feed chamber to cool and lubricate the components of the friction clutch.

Abstract: A method controls a powertrain that directs power from an engine and a transmission to all four wheels or to just front wheels or to just rear wheels. The method includes monitoring information transmitted over a communications network. The method determines whether one or more components of the powertrain are in an active condition or in an inactive condition. The one or more components of the powertrain are in the inactive condition when not connected to the transmission and not connected to the front wheels or the rear wheels. The one or more components of the powertrain are in the active condition when connected to the transmission and connected to the front wheels and the rear wheels. The method switches the one or more components of the powertrain between the inactive condition and the active condition based at least in part on visual data provided by an on-board camera system.

Abstract: A transfer case includes first and second output shafts selectively driven by an input shaft. A first gearset is driven by the input shaft providing first and second gear ratios to the first output shaft. A range actuator includes an axially moveable member operable to shift the first gearset between the first and second gear ratios. An actuation shaft is coupled to the axially moveable member such that rotation of the actuation shaft translates the axially moveable member. A second gearset is driven by the input shaft and drives the actuation shaft. The second gearset includes a control gear moveable into and out of meshed engagement with a first gear and an idler gear. The actuation shaft is rotated in a first direction when the control gear is meshed with the first gear and rotated in an opposite direction when meshed with the idler gear.

Abstract: An electric water pump, and more specifically an electric water pump having an improved wet sleeve so that the water pump is free of a housing. The electric water includes a pump rotor having a shaft. A wetsleeve surrounds the rotor and has a cap, a sleeve that houses the rotor, and a seat in communication with the shaft of the rotor so that the seat assists in supporting the shaft a stator. Surrounding the wet sleeve and the rotor is a volute covering an upper portion of the rotor, wet sleeve, and stator. The electric water pump further includes a rubber boot covering a lower portion of the rotor, wet sleeve, and stator and is in communication with the volute forming a cover.

Abstract: A power transmission device for a four-wheel drive vehicle includes an input shaft adapted to be driven by a power source. A first output shaft is rotatable about a first axis and adapted to transmit torque to a first driveline. A second output shaft is adapted to transmit torque to a second driveline and is rotatable about a second axis. The first and second axes diverge from one another. A transfer unit includes a drive member rotatably supported on the first output shaft and a driven member coupled to the second output shaft. A joint is positioned within a cavity formed in the driven member and drivingly interconnects the driven member and the second output shaft. The driven member includes first and second portions separable from and re-mountable to each other to allow service to the joint.