Abstract: An axle disconnect system is provided whereby axles of a tandem or multi-axle vehicle may be easily and quickly engaged and disengaged as required and whereby the ring gear and differential gears remain stationary when the axle is disengaged. In multi-axle vehicles, a dual disconnect mechanism is contained in the front and auxiliary rear axles. When only the primary rear axle is necessary to propel the vehicle (e.g., during highway use) the transfer case interrupts torque to the front axle. Similarly, a clutch also interrupts torque transmission to the auxiliary rear axle. In this mode, the dual disconnect mechanism prevents the axle output shafts from back-driving the differential, thereby reducing parasitic losses and wear.

Abstract: In a driven axle assembly (12) for a motor vehicle that includes a differential housing located substantially in the center of the axle and tubes (16, 17) extending laterally from the differential, surrounding axle shafts (20) and opening into a lubricant reservoir (60) in the differential housing, a system for circulating and cooling axle lubricant includes a cover (26) for closing and sealing the housing having a first aperture into the housing where a ring gear rotates through the lubricant reservoir. The aperture in the cover opens to a chamber that holds lubricant carried through the aperture by the rotating ring gear. Conduit (72) connected by a hydraulic fitting to the chamber has its opposite end connected to an oil cooler mounted on the axle tube. Conduit (78) returns the lubricant to the reservoir in the differential housing.

Abstract: A pressure control valve assembly is disposed in the hydraulic flow path of a differential assembly and is connected to a passageway leading to a limited slip device within the differential case to establish fluid communication there between. The valve assembly includes a machined or formed blind hole, a groove which partially intersects the blind hole, a ball member seated in the blind hole, and a spring resiliently acting on the ball to apply a force biasing the ball into the blind hole. At the intersection of the blind hole and groove, an area, which is not sealed by the ball, is formed that provides a controlled leakage path for the hydraulic fluid.

Abstract: A push-type expandable fixture provided to secure a work-piece to a rotatable machine. An expandable sleeve is inserted within a bore of a hollow work-piece. The work-piece together with the expandable sleeve is disposed about a pair of wedge members which are in turn secured to a first rotatable portion of the machine. The wedge members engage a corresponding tapered internal surface of the expandable sleeve. The second wedge member is longitudinally displaceable relative to the first wedge member and together extends through the work-piece to engage a second rotatable portion of the machine. As the first and second rotatable portions of the machine are brought toward one another, the wedge members act on the tapered surfaces of the sleeve forcing the sleeve to radially expand and firmly grip the work-piece. The arrangement provides the ability to firmly secure a work-piece to a rotatable machine tool by a simple push-type action without the need to induce compression forces on the work-piece.

Abstract: An ultra narrow adjustable differential assembly includes a ring gear rotatably supported within a differential housing about a central axis, a set of differential pinion mate gears rotatably mounted to the ring gear, a pair of opposite side gears drivingly engaging the differential pinion mate gears for establishing driving connection between the ring gear and the side gears and allowing differential rotation between the side gears, and an adjustment device for selectively adjusting position of the ring gear relative to the differential housing and proper bearing preload.

Abstract: A low spring rate multi-convoluted collapsible spacer adapted for use as a bearing preloading element. The collapsible spacer comprises a substantially tubular body compressible in an axial direction thereof from a predetermined free length to a substantially shorter length. The tubular body includes a yielding zone and an elastic zone adjacent to said yielding zone. Each of the yielding and elastic zones has at least one convolution curved in the same radial direction. An average thickness of the body of the spacer in the elastic zone is substantially greater than an average thickness of the body in the yielding zone that provides the collapsible spacer a substantially higher resiliency in the axial direction in the elastic zone than in the yielding zone. As a whole, the collapsible spacer has a relatively low spring rate, thus larger amount of “spring back”, hence less sensitivity to wear and maladjustment.

Abstract: A hydraulic coupling assembly is provided for an auxiliary drive axle of an all wheel drive motor vehicle. The hydraulic coupling assembly comprises a rotatable casing, first and second output shafts axially outwardly extending from said casing, at least one hydraulically operated, selectively engageable friction clutch assembly for operatively coupling the casing to at least one of the output shafts, and at least one hydraulic clutch actuator. The hydraulic actuator includes a hydraulic pump located within the casing and adapted to generate a hydraulic pressure to frictionally load the friction clutch assembly, and a variable pressure relief valve assembly fluidly communicating with the hydraulic pump to selectively control the hydraulic pressure generated by the pump. The variable pressure relief valve assembly includes an electro-magnetic actuator selectively for varying a release pressure of the pressure relief valve assembly based on a magnitude of an electric current applied thereto.

Abstract: A rigid drive axle assembly for motor vehicles, includes a support beam member having a substantially flat, enlarged central section and two opposite arm sections axially outwardly extending from the central section, a differential assembly secured to the flat central section of the support beam member, and two opposite axle shaft members outwardly extending from the differential assembly and rotatably supported by the arm sections in a spaced relationship with respect to the central section of the support beam member. The differential assembly includes a differential carrier frame member fastened to the central section of the support beam member, and provided for rotatably supporting a differential case and a drive pinion. The differential assembly is enclosed into a housing formed by a rear cover and a front cover secured to opposite surfaces of the central section of the support beam member. The rear cover incorporates two throughholes provided with self-centering seals.

Abstract: A method and apparatus to independently measure the bearing pre-load of a pinion gear and differential case an assembled axle assembly. The ring gear and pinion gear are positioned within a backlash so that there is no engagement therebetween. The pinion shaft and differential case are rotated in synchronization maintaining the relative positions and the torque to rotate the pinion shaft and differential case are independently measured. Once the independent pre-loads are measured, the ring gear is allowed to freely rotate being driven by the pinion gear and the overall torque to rotate the entire axle assembly can be measured.

Abstract: A power transmission apparatus comprises a device for transmitting power by frictional force between first and second rotary members rotated relative to each other; a device for pressing the power transmitting device in a direction of increasing frictional force; and a hydraulic fluid delivery system for driving the pressing device in the direction of increasing frictional force, whereby the fluid delivery system is driven by a drive pinion gear stem. In accordance with this invention, the need for a separate hydraulic motor and pump or drive belts is eliminated thereby reducing the complexity and size of the apparatus while providing increases reliability as compared to alternative designs. The present invention also provides a unique advantage of utilizing the axle's own lubricant, thus avoiding potential cross-contamination between a specialized hydraulic fluid and the axle lubricant.

Abstract: A limited slip differential having a modified clutch pack mechanism located outside of the differential case. The mechanism include a planetary gear assembly disposed between a side gear and the clutch pack to facilitate the application of greater torque. A rotatable collar and cup-shape member together with a pair of planetary gear sets establish a driving connection through the differential case between the side gear and the clutch pack. Clutch plates are alternatively splined on the cup-shaped member and differential case to facilitate selectively coupling therebetween. The incorporation of the external clutch pack and planetary gear set facilitate the use of a greater diameter clutch plates resulting in greater torque capability.

Abstract: A limited slip differential includes a friction clutch mechanism, an electromagnetic coupling, and a camming mechanism disposed between the friction clutch mechanism and the electromagnetic coupling. The camming mechanism converts shearing forces within the electromagnetic coupling to an axial force applied to engage the clutch mechanism. The camming mechanism includes annular discs having axially inclined ramps, and a roller bearing for movement along the ramps to provide for variable spacing between the annular discs, wherein increased spacing is used to apply the axial force.

Abstract: A novel arrangement of a pinion shaft for a differential assembly having a substantially H-shaped cross-section with added oiling radii. The H-shaped pinion shaft provides substantially reduced weight of the differential pinion shaft, increases a strength-to-weight ratio, and improves lubrication.

Abstract: A collar for a clutch, particularly a clutch used in selectively connecting and disconnecting a source of drive torque with a co-axial driven shaft. More particularly, the present invention relates to a collar wherein meshing surfaces of the torque source and the driven shaft are designed such that the collar is under a neutral axial force while under torque. The shift collar is splined to a rotating shaft and is slideable along the direction of the longitudinal axis of the shaft. Translation of the shift collar is preferably performed by means of a shift mechanism in association with a detent ball, used to self-lock the shift collar in place under torque load. When the shift mechanism and detent ball are moved to release the shift collar, the angle teeth and splines cause the shift collar to disengage, even under high torque load.

Abstract: A dual disconnect differential assembly for four-wheel drive (4WD) vehicle is disclosed. This disconnect differential assembly connects/disconnects both axle shafts of a differential assembly simultaneously from the side gears of the differential assembly. Both axle shafts are interconnected to provide simultaneous sliding along an axial direction. A clutch mechanism associated with the two differential side gears (which may be otherwise conventional) and with the axle shafts is provided for simultaneous connection and simultaneous disconnection of the axle shafts. The dual disconnect differential assembly herein is simple, compact, and reliable. It overcomes the disadvantages associated with single axle disconnect mechanisms presently in use. It also provides a simpler, more compact, and more reliable dual disconnect differential mechanism than any such mechanism presently known.

Abstract: A speed-sensing system for a differential assembly, wherein a tone ring positioned on the ring gear flange is eliminated and the speed-sensing equipment is specially placed in the form of a thrust washer and/or slinger with a tone sensing ring disposed between the yoke and the inner race of the pinion shaft to avoid bending distortions of the ring gear under various dynamic load conditions.

Abstract: An electronically controlled locking differential assembly including a friction clutch assembly provided within a differential case for selectively restricting differential action. The friction clutch assembly is actuated by a selectively controllable actuator including an electrical motor externally mounted to an axle housing, a reduction gearing and a drive screw adapted to axially displace a pusher block when the drive motor is actuated. The pusher block is integrally secured to a clutch actuating sleeve adapted to slide within a differential case trunnion coaxially to the side gear. The actuating sleeve is provided to apply a clutch loading force to an actuator plate. When the drive motor is actuated by a signal from a control unit, the rotary motion of the drive screw is transmitted to the actuator plate via the pusher block and the actuating sleeve, thereby actuating the friction clutch assembly and locking the differential.

Abstract: A method for controlling an axle shaft endplay in a differential assembly is disclosed. The desired axle shaft endplay is determined by a differential manufacturer based on the specific operating conditions of the differential assembly. In accordance with the endplay controlling method of the present invention, first the differential is partially assembled by mounting side gears and a differential pinion shaft carrying pinions in a differential case. Then, the manufacturer determines a thickness of an axle shaft-retaining ring that would provide the desired endplay. The manufacturer is provided with an endplay controlling kit of a plurality of the retaining rings of assorted thickness. The appropriate retaining ring is selected from the kit having the thickness as determined in the previous step. Next, axle shafts are inserted into the differential case through the side gears, and the selected retaining ring is mounted to the axle shafts. After this step, the assembly of the differential is completed.

Abstract: A limited slip differential for vehicular applications that eliminates chattering noise from the differential while maintaining seal integrity. This is accomplished by the use of a differential casing that includes at least a pair of fluid seals isolating a first chamber for bathing the respective differential components in a fluid lubricant appropriate to the contained components. A fluid lubricant, such as one containing a friction modifier is particularly suitable for the array of friction plates and pads of a disk pack, but can be detrimental to sealing elements, such as about the pinion gear. The separate chambers allows for the use of different fluid lubricants.

Abstract: A bushing installation and removal assembly includes mounting table fitted with a vice fixture, a press/ram assembly having a controlled hydraulic press whereby a separate hydraulic repositioning system disposes the work piece into the press/ram assembly in a controlled manner. The worktable, fixtures and press/ram assembly are designed to receive and securely position the housing assembly (work piece) onto a controlled substrate. The substrate is then designed to reposition the housing assembly (work piece) proximate to the press ram, which suitably presses the bushing member onto the housing assembly (work piece). The substrate is then retracted to its original position where the housing assembly (work piece) is removed for further processing.