Abstract: A power transfer device for a motor vehicle having a modular housing assembly which supports a geartrain. A first embodiment of the modular housing assembly includes a case having unitary sidewall with terminal edges defining two opposed openings. The sidewall also defines an interior chamber and the openings are enclosed by a pair of cover plates. Pillow blocks are used to support the drive components of the geartrain within the chamber and are secured to shelves which extend from the sidewall. Loads created during operation are transmitted from the geartrain to the sidewall. The cover plates are secured to the terminal edges of the sidewall using a plurality of U-shaped spring clamps. A second embodiment of the modular housing assembly includes a box-like case having one open side. A cover plate is used to enclose the geartrain and lubrication fluid within the interior volume of the box-like case.

Abstract: A full-time power transfer system is disclosed to include a transfer case having a clutch assembly arranged to control speed differentiation and torque biasing across an interaxle differential, sensors for detecting and generating sensor signals indicative of various dynamic and operational characteristics of the vehicle, and a controller for controlling actuation of the clutch assembly in response to the sensor signals. Upon the occurrence of traction loss, the clutch assembly is automatically actuated for limiting interaxle slip while transferring increased drive torque to the non-slipping driveline. Under a preferred adaptive control scheme, the actuated condition of the clutch assembly is controllably modulated between its non-actuated and fully-actuated limits for automatically varying the magnitude of speed differentiation and torque biasing across the interaxle differential in response to changes in the dynamic and operational characteristics of the vehicle.

Abstract: An endplay adjustment mechanism for a co-linear shaft assembly. More specifically, the co-linear shaft assembly includes an input shaft and a mainshaft aligned along a common longitudinal axis. A threaded adjuster plug and a thrust bearing are interdisposed between the input shaft and the mainshaft to permit relative longitudinal positioning therebetween. Accordingly, after the shaft assembly has been assembled into a power transmission device, the threaded adjuster plug is tightened to effectively increase the length of the co-linear shaft assembly, thereby eliminating any excess endplay of the shafts relative to the housing of the power transmission apparatus.

Abstract: A transmission for a four-wheel drive vehicle having a multi-speed geartrain and power transfer mechanism incorporated into a common housing assembly. The multi-speed geartrain includes a input shaft, a mainshaft, and a plurality of constant-mesh gearsets arranged for selectively coupling the mainshaft to the input shaft for driven rotation at various speed ratios. The mainshaft can be selectively coupled to the power transfer mechanism for establishing two alternative power transmission routes. In particular, a range shift mechanism is provided for establishing a high-range power transmission route and a low-range power transmission route from the mainshaft to the input of an interaxle differential. The torque delivered to the interaxle differential is split between the front and rear drivelines to establish a full-time four-wheel drive mode. A transfer clutch is provided for automatically controlling slip and torque biasing between the outputs of the interaxle differential.

Abstract: A transfer case for a four-wheel drive vehicle having a planetary gear assembly which integrates a gear reduction unit and an interaxle differential into a common assembly. A synchronized range clutch is operably associated with the input to the planetary gear assembly and can be selectively shifted on-the-fly for establishing high-range and low-range speed ratios. A synchronized mode clutch is operably associated with the output of the planetary gear assembly and can be selectively shifted on-the-fly for establishing two-wheel, full-time four-wheel and locked four-wheel drive modes.

Abstract: A transmission compounder assembly having a one-way clutch between an input shaft and an output shaft to establish a direct-ratio drive path therebetween. A planetary gearset can be selectively engaged to establish a compound-ratio drive path between the shafts. The planetary gearset includes a sun gear, a ring gear fixed to the output shaft, a carrier fixed to the input shaft, and a plurality of planet gears rotatably supported from the carrier and meshed with both the ring gear and the sun gear. A band brake is provided for selectively braking the sun gear. A controllable overrunning clutch is mounted between the carrier and the sun gear and can be selectively shifted between a locked mode and a released mode. The compounder assembly further includes an actuator for controlling actuation of the band brake and the overrunning clutch.

Abstract: An electronically controlled shift system is provided for a synchronized manual transmission of a motor vehicle. The shift system provides greater control of gear engagement by determining an optimum shift force at shift time, by adjusting this shift force based upon engine temperature, and by applying variable shift forces to complete a gear shift. In particular, the electronically controlled shift system comprises a manually operated shift lever for selecting a gear, a transmission control module connected to the shift lever for receiving an electrical input signal indicative of a selected gear and a dual motion actuator receiving actuation signals from the transmission control module for actuating a shift rail of the transmission to engage the selected gear.

Abstract: A hydraulic coupling including a multi-plate clutch assembly operably connecting two relatively rotatable members and an actuator assembly for actuating the clutch assembly in response to speed differentiation between the two rotary members. The actuator assembly includes a hydraulic pump, a piston disposed in a piston chamber, and a fluid distribution system including a first flow path for supplying hydraulic fluid from a sump to the hydraulic pump and a second flow path for supplying hydraulic fluid from the hydraulic pump to the piston chamber. Hydraulic pressure in the piston chamber controls the magnitude of the clutch engagement force exerted by the piston on the clutch assembly. The fluid distribution system further includes a third flow path between the piston chamber and a clutch chamber.

Abstract: A transmission for a four-wheel drive vehicle having a multi-speed geartrain and power transfer mechanism incorporated into a common housing assembly. The multi-speed geartrain includes a input shaft, a mainshaft, and a plurality of constant-mesh gearsets arranged for selectively coupling the mainshaft to the input shaft for driven rotation at various speed ratios. The mainshaft can be selectively coupled to the power transfer mechanism for establishing two alternative power transmission routes. In particular, a range shift mechanism is provided for establishing a high-range power transmission route and a low-range power transmission route from the mainshaft to the input of an interaxle differential. The torque delivered to the interaxle differential is split between the front and rear drivelines to establish a full-time four-wheel drive mode. A transfer clutch is provided for automatically controlling slip and torque biasing between the outputs of the interaxle differential.

Abstract: A split planetary gear assembly having a pair of helical gearsets. The first helical gearset includes a first sun gear, a first ring gear, and a set of first planet gears meshed with the first sun gear and the first ring gear. The second helical gearset includes a second sun gear, a second ring gear, and a set of second planet gears meshed with the second sun gear and the second ring gear. The components of the second helical gearset have the same number of teeth, helix angle, and tooth pitch as the components of the first helical gearset with the exceptions that their angular helix orientation (i.e., left-hand/right-hand) is reversed and they are circumferentially indexed by one-half tooth pitch. In addition, the first and second planet gears are arranged in paired sets and supported on a common pinion shaft which, in turn, is fixed to a planet carrier. The second sun gear is splined for rotation with and limited axial movement relative to the first sun gear.

Abstract: A transfer case for a four-wheel drive vehicle having a planetary gear assembly which integrates a gear reduction unit and an interaxle differential into a common assembly. A synchronized range clutch is operably associated with the input to the planetary gear assembly and can be selectively shifted on-the-fly for establishing high-range and low-range speed ratios. A synchronized mode clutch is operably associated with the output of the planetary gear assembly and can be selectively shifted on-the-fly for establishing two-wheel, full-time four-wheel and locked four-wheel drive modes.

Abstract: A hydraulic coupling is disclosed for use in motor vehicle driveline applications to rotatively couple a pair of rotary members. The hydraulic coupling includes a multi-plate clutch assembly operatively connecting the two rotary members and an actuator assembly for actuating the clutch assembly in response to and as a function of speed differentiation between the two rotary members. The actuator assembly includes a hydraulic pump, a piston disposed in a piston chamber, and a fluid control system for controlling the fluid pressure supplied to the piston chamber by the hydraulic pump to control the clutch engagement force exerted by the piston on the clutch assembly. The fluid control system includes a pressure relief valve operable for limiting the fluid pressure in the piston chamber to a predetermined maximum pressure value.

Abstract: A clutched actuator for use in a transfer case is disclosed which may be used in conjunction with electronic traction control systems and anti-lock braking systems where the clutched actuator system is required to quickly disengage the four-wheel drive of the vehicle. The clutched actuator is operably coupled to the transfer case of the vehicle drive system through a sector plate. The clutched actuator includes a worm drive motor assembly providing the base driving mechanism, a clutching mechanism, and a gear reduction mechanism for reducing the torque capacity required of the clutch mechanism. When the clutching mechanism is engaged, power is transmitted from the worm drive through the gear reduction mechanism to the output shaft to selectively engage the mode of operation of the transfer case, i.e., two-wheel or four-wheel drive mode, and the drive torque distribution between the front and rear wheels. The worm gear is non-backdrivable such that the motor need not provide a holding torque.

Abstract: A differential assembly is disclosed having a pair of hydraulic couplings installed in a differential casing and operably arranged to rotatively couple first and second rotary members to the differential casing. Each hydraulic coupling includes a clutch pack operatively connected between one of the rotary members and the casing, a hydraulic pump, and a fluid distribution system for delivering pumped fluid to a pressure chamber to actuate a piston for engaging the clutch pack and to a clutch chamber to cool the clutch pack.

Abstract: A transfer case having a primary output shaft, a secondary output shaft, and a transfer clutch disposed therebetween. The transfer clutch includes an inner drum journalled on the primary output shaft and which has clutch teeth that are selectively engageable with clutch teeth on the primary output shaft, an outer drum rotatably supported on the primary output shaft and which is fixed for rotation with the secondary output shaft, and a clutch pack operably interconnected between the inner and outer drums.

Abstract: A hydraulic coupling for use in motor vehicle driveline applications to limit speed differentiation and transfer drive torque between two rotary members. The hydraulic coupling includes a multi-plate clutch assembly operably connecting the two relatively rotatable members, and a sealed actuator assembly for actuating the clutch assembly in response to the magnitude of speed differentiation between the two rotary members. The actuator assembly includes a hydraulic pump and a piston which are sealed relative to the clutch assembly. The sealed actuator assembly includes an internal recirculation path for supplying hydraulic fluid retained therein between a low pressure supply chamber at the inlet side of the hydraulic pump and a high pressure piston chamber provided at the discharge side of the hydraulic pump. Hydraulic pressure in the piston chamber controls the magnitude of the clutch engagement force exerted by the piston on the clutch assembly.

Abstract: A transfer case is disclosed for a four-wheel drive vehicle. The transfer case includes an interaxle differential and a transfer clutch for controlling speed differentiation and torque biasing across the interaxle differential. A mode shift mechanism is provided for selectively coupling one or more components of the interaxle differential to the input shaft for establishing a full-time four-wheel drive mode, a locked four-wheel drive mode, and a Neutral mode. A controller controls actuation of the transfer clutch and the mode shift mechanism in response to a mode signal indicating which drive mode has been selected by the vehicle operation.

Abstract: A compact six-speed fully-synchronized manual transaxle includes an input shaft having four fixed input gears, a first intermediate shaft rotatably supporting four speed gears meshing with four of the input gears, a second intermediate shaft rotatably supporting two speed gears meshed with two of the input gears and a reverse gear meshed with a speed gear on the first intermediate shaft, and a differential. A transfer gear on each intermediate shaft is meshed with a final drive gear fixed to the differential.

Abstract: A transmission compounder assembly comprising an input shaft, an output shaft and a one-way clutch operable to establish a direct-ratio drive path between the shafts. A planetary gearset can be selectively engaged to establish a compound-ratio drive path between the shafts. The planetary gearset includes a sun gear, a ring gear fixed to the output shaft, a carrier fixed to the input shaft, and a plurality of planet gears rotatably supported from the carrier and meshed with both the ring gear and the sun gear. A band brake is provided for selectively braking the sun gear. A clutch pack is mounted between the carrier and the sun gear and can be selectively actuated to prevent relative rotation therebetween. The compounder assembly further includes a brake actuator for controlling actuation of the band brake and a clutch actuator for controlling actuation of the clutch pack.

Abstract: A transfer case for a four-wheel drive vehicle having a planetary gear assembly and a synchronized range clutch which can be selectively shifted on-the-move establishing high-range and low-range drive modes. The planetary gear assembly includes a ring gear, a sun gear, a carrier coupled for rotation with an output shaft of the transfer case, and a pinion gear rotatably supported from the carrier and which is meshed with the ring gear and the sun gear. The range clutch includes a first sleeve coupled for rotation with the ring gear and which is rotatably supported from a second sleeve coupled for rotation with an input shaft of the transfer case. With the range clutch in a first position, the first sleeve is uncoupled from the housing and the second sleeve is coupled to the carrier for driving the output shaft at a first speed ratio relative to the input shaft.