Abstract: A torque transmitting assembly including a first drum having a plurality of teeth formed at an end thereof. A gear assembly axially aligns with the first drum and has a plurality of teeth intermeshing with the plurality of teeth of the drum. The gear assembly includes an annular gear and a plate axially aligning with the gear.

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 torque transmitting assembly is provided. The torque transmitting assembly includes a generally cup shaped outer shell having a closed end and an open end. The closed end has at least one raised portion formed therein. The outer shell includes an outwardly extending lip surrounding the open end of the outer shell. The open end of the outer shell is adapted to be operatively engaged with a first rotating member. A generally disk shaped inner member has a central aperture and a central axis. The inner member includes at least one tab extending axially outwardly therefrom and engages the raised portion of the outer shell to facilitate a transfer of rotation between the outer shell and the inner member. The central aperture is adapted to be operatively engaged with a second rotating member. The inner member is received inside said outer shell.

Abstract: A differential case assembly includes a differential case and an integral end cap and ring gear assembly. The differential case has an open end and a side wall with an exterior surface. The integral end cap and ring gear assembly is disposed over the open end of the differential case and adjacent the exterior surface. A first interior portion of the integral end cap and ring gear assembly abuts the exterior surface of the differential case to define a weld joint interface. The integral end cap and ring gear assembly is configured to permit a welding operation at the weld joint interface.

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 method and tool for producing a flow formed part are disclosed, wherein the tool has an annular array of spline forming recesses for producing a flow formed part having splines and machining and production costs are minimized and efficiency is maximized.

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 torque transmitting assembly is provided. The torque transmitting assembly includes a generally cup shaped outer shell having a closed end and an open end. The closed end has at least one raised portion formed therein. The outer shell includes an outwardly extending lip surrounding the open end of the outer shell. The open end of the outer shell is adapted to be operatively engaged with a first rotating member. A generally disk shaped inner member has a central aperture and a central axis. The inner member includes at least one tab extending axially outwardly therefrom and engages the raised portion of the outer shell to facilitate a transfer of rotation between the outer shell and the inner member. The central aperture is adapted to be operatively engaged with a second rotating member. The inner member is received inside said outer shell.

Abstract: A method and tool for producing a flow formed part are disclosed, wherein the tool has an annular array of spline forming recesses for producing a flow formed part having splines and machining and production costs are minimized and efficiency is maximized.

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 internally splined component for transmitting torque wherein the splines are cold formed to predetermined tolerances.

Abstract: An improvement in manufacturing and resulting structure of a torque transmitting assembly for use in a vehicle transmission which transmits torque from a first rotating member to a second rotating member wherein production efficiency is maximized and production costs are minimized.

Abstract: An externally splined clutch hub and method for making the same is disclosed wherein a flat circular metal preform with a central opening is provided and contacted with a single forging die to simultaneously cold forge a centrally disposed tubular neck extending outwardly from one side of the preform and simultaneously a splined annular ring at the periphery of the preform and extending outwardly from the other side of the preform wherein the tubular neck and the annular ring are coaxial.

Abstract: A method of producing a torque transmission between a driving member and a driven member including the steps of capturing an annular gear within the interior of a hollow cylindrical shell formed of a formable material which is caused to be flow formed around a portion of the exterior of the gear to militate against any relative longitudinal and axial movement between the shell and the gear.

Abstract: An improvement in manufacturing and resulting structure of a torque transmitting assembly for use in a vehicle transmission which transmits torque from a first rotating member to a second rotating member wherein production efficiency is maximized and production costs are minimized.

Abstract: The method of producing a pinion carrier comprised of two cold form cooperating carrier components, each consisting of an aperture relatively flat plate having legs extending transversely from the plate; assembling the components so that the legs of one of the components abutted the legs of the other component, and welding the abutting legs together.