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 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 transfer case equipped with a dual-planetary gear reduction unit and a synchronized range shift mechanism operable for permitting 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 transfer case is also equipped with an electronically-controlled 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 drive unit for use with an electric vehicle comprising a planetary gear arrangement. The planetary arrangement includes a reduction portion and a differential portion and provides a large reduction of rotational speed between the motor and the differential portion while delivering differentiated power to the drive wheels. The planetary arrangement includes, in its preferred embodiment, a first ring gear grounded to the transmission housing, a first pinion carrier having a first set of pinions, a first sun gear formed on an input shaft, a second carrier mated with a first output shaft, the second carrier having a second set of pinions, a compound ring-sun gear operatively situated between the first and second sets of pinions, and a second sun gear formed on a second output shaft, the second sun gear being operatively mated with the second set of pinions.

Abstract: A two-piece sector plate is employed in an automotive vehicle transfer case. The sector includes a rotatable body and a cam block movably coupled thereto with a biasing device disposed therebetween. A shift rail mode pin rides along a camming surface of the cam block and along a camming surface of the sector body, wherein the camming surfaces have different radii. A method of operating the two-piece sector plate is also provided.

Abstract: The present invention is directed to a two-speed gear reduction unit and a shift mechanism for establishing two distinct speed ratio drive connections between an input member and an output member. More specifically, the shift mechanism includes a clutch apparatus for stopping relative rotation between the input and output members prior to shifting the gear reduction unit from its neutral operating state into either of its high-range or low-range operating states. Thus, the present invention is adapted for use in the transfer case of a four-wheel drive vehicle for shifting between four-wheel high-range and low-range drive modes.

Abstract: A bearing retention system for use in mounting a bearing assembly. The bearing retention system includes a retainer stud having an elongated head that is used to axially restrain a race of the bearing assembly and a locknut that is used to tighten the retainer stud.

Abstract: The transmission of the present invention includes a multi-speed geartrain comprised of an 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 arrangement for establishing two alternative power transmission routes. In particular, the range shift mechanism is provided for establishing a high-range power transmission route and a low-range power transmission route from the mainshaft to a quill shaft which, in turn, drives the interaxle differential. The torque delivered by the quill shaft is split by the interaxle differential between the front and rear drivelines to establish the full-time four-wheel high-range and low-range drive modes.

Abstract: The present invention is directed to an improved power transfer system for use in four-wheel drive vehicles having a transfer case equipped with a torque transfer arrangement that is operable for automatically controlling the drive torque delivered to the front and rear drivelines of the vehicle and establishing an on-demand four-wheel drive mode.

Abstract: A compact manual transaxle includes an input shaft having four fixed input gears, a first intermediate shaft rotatably supporting three speed gears meshing with three of the input gears, a second intermediate shaft rotatably supporting a pair of 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. One speed gear on each of the intermediate shafts meshes with a common input gear. A transfer gear on each intermediate shaft is meshed with a final drive gear fixed to the differential. The transaxle further includes a pair of synchronizer clutches for establishing three forward gears by selectively coupling the three speed gears to the first intermediate shaft and a pair of synchronizer clutches for establishing two forward gears and the reverse gear by selectively coupling the 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 dual-planetary 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 power transfer system is disclosed for a full-time four-wheel drive vehicle. The power transfer system includes a layshaft 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 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 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 arrangement. A clutch apparatus is operably associated with the planetary gear assembly and can be selectively shifted on-the-fly for establishing a full-time four-wheel high-range drive mode, a neutral non-driven mode, and a full-time four-wheel low-range drive mode.

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 layshaft 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 electronically-controlled 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 compact manual transaxle includes an input shaft having five 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 a speed gear meshed with the other input gear 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. The transaxle further includes a pair of synchronizer clutches for establishing four forward gears by selectively coupling the four speed gears to the first intermediate shaft and a synchronizer clutch for establishing one additional forward gear and the reverse gear by selectively coupling the speed gear and reverse gear to the second intermediate shaft.

Abstract: A power transfer system for a four-wheel drive vehicle is disclosed having a transfer case with its input angled relative to its outputs by means of a constant velocity (CV) universal joint. More specifically, the transfer case input includes a first rotary member adapted to be rotatably driven about the rotary axis of the transmission output shaft, a second rotary member supported for rotation about a second rotary axis that is angled relative to the first rotary axis, and a CV joint interconnecting the first and second rotary members. The transfer case outputs include a pair of rotary output members supported for relative rotation about a common third rotary axis that is offset from the second rotary axis. A torque transfer arrangement is provided for transferring torque from the transfer case input to its outputs. As such, the CV joint allows the transfer case to be angulated so that reduced departure angles are achieved with respect to the prop shaft connections.

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 dual-planetary gear reduction unit that is operable for establishing high-range and low-range speed ratios, and a powershift 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 mode clutch operable for controlling the magnitude of speed differentiation and torque biasing across the interaxle differential.

Abstract: An oil distributing apparatus for use with a transmission, and method for producing the same, are disclosed to provide an improved lubrication system for supplying lubricating fluid to certain areas of the transmission. The improved lubrication system includes an oil distributing apparatus having an end plate connectable to a transmission housing and an oil dam connected to the end plate to form an oil chamber therebetween that is hydraulically connectable to a supply of lubricating fluid in the transmission. The oil chamber provides a flow path that is substantially isolated from the turbulence inducing effects of the rotating shafts and associated bearings in the transmission.

Abstract: An improved geartrain includes a transmission unit operatively attached to a longitudinally placed engine. The transmission unit incorporates a multi-speed transmission and a lockable planetary differential and further includes an input shaft, an output shaft, and connecting drive and drive and gears. Two alternative torque paths are provided to a quill shaft from the output shaft. One of these paths is a high-range path and the other of these is a low-range path. The two torque paths are directed through a synchronizer clutch between low-range and high-range. One end of the quill shaft is connected to the low-high synchronizer clutch and the other end is connected to the lockable differential. The differential end of the quill shaft is connected to the pinion carrier of the differential. The torque delivered by the quill shaft is split by the differential when in its unlocked mode with a portion going to the rear wheels and a potion going to the front wheels.

Abstract: The present invention is directed to an improved "on-demand" power transfer system of the type having a transfer case incorporated into the driveline of a four-wheel drive vehicle. The transfer case is arranged to normally deliver drive torque to the driven wheels so as to establish a two-wheel drive mode of operation. In addition, the transfer mechanism is equipped with a clutch assembly for selectively delivering drive torque to the non-driven wheels for establishing an on-demand four-wheel drive mode of operation. The transfer mechanism is also equipped with a rotary actuator and a drive mechanism for actuating the clutch assembly. The power transfer system further includes sensors for detecting various dynamic and operational characteristics of the vehicle and generating sensor input signals indicative thereof. A controller is provided for processing the input signals and controlling actuation of the rotary actuator in response thereto.

Abstract: A synchronizer unit eliminates the chattering noise generated when shifting a manual transmission into reverse from a forward gear while the drive shaft continues to rotate in the direction corresponding with the forward gear by providing a reverse brake arrangement for arresting rotation of the input shaft. The reverse brake arrangement includes a shaft rotatably supported by the transmission housing and a clutch hub mounted on the shaft which is adapted to rotate with the shaft. The clutch hub has a splined outer circumference. A shift sleeve is provided for engagement with the splined outer circumference of the clutch hub and is movable in the axial direction of the shaft. The reverse brake mechanism further includes a frustoconical cone in coaxial relation to the shaft and disposed on a first side of the clutch hub. The frustoconical cone includes a frustoconical surface on its outer periphery. A first blocker ring is coaxially aligned with the shaft.