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 hydraulic coupling includes a clutch assembly operatively connecting two rotary members and an actuator assembly for actuating the clutch assembly in response to speed differentiation between the two rotary members. The clutch assembly includes a multi-plate clutch pack alternately connected between the two rotary members within a clutch chamber. The actuator assembly includes a hydraulic pump, a piston disposed in a piston chamber, and a fluid distribution system having a first flow path between a supply chamber and the hydraulic pump, a second flow path between the hydraulic pump and the piston chamber, and a third flow path between the hydraulic pump and the clutch chamber. The fluid delivered to the piston chamber controls engagement of the piston with the clutch pack for controlling actuation of the clutch assembly. Additionally, the fluid delivered to the clutch chamber is used to cool and lubricate the clutch pack.

Abstract: A shift fork/gate assembly is provided for use in a manual transmission of the type including a gear train having a plurality of gears disposed thereon and a shift control assembly for selecting one of the plurality of gears. The shift fork/gate assembly includes a shift fork member engaging a synchronizer device along the gear train. A gate member is connected to the fork member by inserting a portion of the gate member into an aperture formed in the fork member. The gate member selectively cooperates with a blocker of the shift control assembly to selectively prevent movement of the shift fork member until the shift control assembly is properly aligned.

Abstract: The present invention is directed to a six-speed manual transmission comprised of an input shaft, an output shaft, first and second input gears fixed to the input shaft in mesh with first and second speed gears rotatably supported on the output shaft, third and fourth input gears rotatably supported on the input shaft, an output gear rotatably supported on the output shaft and having a third speed gear meshed with the third input gear and a fourth speed gear meshed with the fourth input gear, a first transfer gear meshed with the fourth speed gear, a second transfer gear, a third transfer gear fixed to the output shaft and meshed with the second transfer gear, a first clutch for selectively coupling either of the first and second speed gears to the output shaft, a second clutch for selectively coupling either of the third and fourth input gears to the input shaft, a third clutch for selectively coupling the first transfer gear to the second transfer gear, and a fourth clutch for selectively coupling the outpu

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 for establishing four-wheel high-range and low-range drive modes.

Abstract: A bi-directional fluid pump for providing a source of pressurized fluid. The fluid pump includes a gerotor assembly, an inlet valve system, and an outlet valve system which work cooperatively to provide pressurized fluid during two directions of rotation.

Abstract: A transfer case includes an input shaft driven by the output of an engine and transmission, a first output shaft connected to a first driveline, a second output shaft connected to a second driveline, and a power transfer mechanism for transferring drive torque from the input shaft to at least one of the output shafts. The power transfer mechanism includes a gear reduction unit driven by the input shaft and a range clutch operable for engaging the gear reduction unit to establish high-range and low-range drive modes between the input shaft and the first output shaft. A transfer case shift control system controls actuation of the range clutch during motive operation of the motor vehicle, thereby permitting on-the-move shifting of the transfer case between its high-range and low-range drive modes.

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 synchronized range shift mechanism is provided for establishing a high-range transmission route and a low-range transmission route from the mainshaft to a primary driveline to define a two-wheel drive mode. A portion of the drive torque delivered to the primary driveline can be transferred automatically through a transfer clutch to the secondary driveline to establish an on-demand four-wheel drive mode.

Abstract: A manual transmission for use in motor vehicles is disclosed. The transmission includes an input shaft, an output shaft, and a plurality of constant-mesh gearsets that can be selectively engaged for establishing corresponding forward gears therebetween. In addition, a reverse gear assembly is provided for establishing the reverse gear. The reverse gear assembly includes an idler shaft non-rotatably mounted within a housing of the transmission and an idler gear journally supported on the idler shaft. The idler gear is linearly movable into engagement with a reverse input gear and a reverse speed gear. Each tooth of the reverse idler gear includes a pair of intersecting flank radii which intersect at the tooth centerline, creating an included angle therebetween. The teeth of the input and output gears are similarly formed to include a pair of flank radii and included angles.

Abstract: A synchronizer clutch having a first member, a second member, and a clutch pack. The clutch pack includes a first clutch plate fixed to the first member and a second clutch plate fixed to the second member. The synchronizer clutch further includes a clutch hub fixed to the first member, a first ring located between the clutch hub and the clutch pack, and a second ring frictionally engaging said first ring. A shift sleeve is mounted for rotation with the clutch hub and sliding movement thereon between a first and second position. In the first position, the shift sleeve uncouples the first member from the second member to enable relative rotation therebetween. In the second position, the shift sleeve couples the first member to the second member for preventing relative rotation therebetween.

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: An adapter for installation between a single-offset transfer case and a transmission unit. The adapter includes an adapter input shaft coupled to an output shaft of the transmission, an adapter output shaft coupled to an input shaft of the transfer case, and a drive mechanism connecting the adapter input and output shafts. The adapter input shaft is rotatably driven by the transmission output shaft about a first rotary axis. The adapter output shaft is rotatably driven by the adapter input shaft about a second rotary axis. The input shaft and a first output shaft of the transfer case are commonly aligned for rotation with adapter output shaft for rotation about the second rotary axis. The transfer case has a second output shaft supported for rotation about a third rotary axis.

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 for establishing four-wheel high-range and low-range drive modes.

Abstract: A gear shift tower assembly for a manual transmission of a motorized vehicle having a housing adapted to be secured to the manual transmission, a gimbal pivotally coupled to the housing for rotation about a first axis, a shift lever pivotally coupled to the gimbal for rotation about a second axis, and a centering mechanism for biasing the shift lever to a centered position relative to the housing is disclosed. The centering mechanism includes a camming surface formed on the gimbal and a spring-biased follower operably coupled to the housing and engaging the camming surface to urge the shift lever toward a desired position.

Abstract: A manual transmission for use in motor vehicles is disclosed. The transmission includes an input shaft, an output shaft, and a plurality of constant-mesh gearsets that can be selectively engaged for establishing corresponding forward gears therebetween. In addition, a reverse gear assembly is provided for establishing the reverse gear. The reverse gear assembly includes an idler shaft, a first idler gear rotatably supported on the idler shaft and which is driven by the input shaft, a second idler gear fixed to the idler shaft and meshed with a reverse output gear fixed for rotation with the output shaft, and a synchronizer clutch operable for selectively coupling the first idler gear to the idler shaft to establish the reverse 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 compact manual transmission includes an input shaft having four fixed input gears, a first intermediate shaft rotatably supporting two speed gears meshing with two of the input gears, a second intermediate shaft rotatably supporting three speed gears meshed with three of the input gears and a reverse gear meshed with a speed gear on the first intermediate shaft, and an output shaft. Two speed gears on each of the intermediate shafts meshes with common input gears. A transfer gear on each intermediate shaft is meshed with the output shaft. The transmission further includes a synchronizer clutch for establishing two forward gears by selectively coupling the two speed gears to the first intermediate shaft and a pair of synchronizer clutches for establishing three forward gears and the reverse gear by selectively coupling the three speed gears and reverse gear to the second intermediate shaft.

Abstract: A power transfer system is disclosed for a four-wheel drive vehicle operable for permitting a vehicle operator to select between various full-time and part-time four-wheel drive modes. The power transfer system includes a dualplanetary gear reduction unit that is operable for establishing high-range and low-range speed ratios, and a synchronized range shift mechanism that is adapted to permit the vehicle operator to shift on-the-fly for establishing full-time and part-time high-range and low-range four-wheel drive modes. The power transfer system includes an slip limiting/torque-biasing arrangement including an interaxle differential and a transfer clutch operable for controlling the magnitude of speed differentiation and torque biasing across the interaxle differential.

Abstract: A hydraulic shift system for a four-wheel drive transfer case is disclosed. The hydraulic shift system includes a pump, a pressure regulator, an accumulator, a control valve, a range shift assembly, a mode shift assembly, and a shift actuator. The pump supplies hydraulic pressure to the accumulator which is in communication with the control valve. The shift actuator controls the delivery of hydraulic pressure from the control valve to the range shift assembly and the mode shift assembly in response to actuation by the vehicle operator of a mode select mechanism.

Abstract: A transfer case for a four-wheel drive vehicle having a planetary gear assembly and a synchronized range clutch operably associated with the input to the planetary gear assembly which can be selectively shifted on-the-fly for establishing high-range and low-range speed ratios. A mode clutch is operably disposed between the front and rear output shafts and can be selectively or automatically shifted for establishing a four-wheel drive mode.