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: In a differential/mechanism for transmitting power from a drive shaft to the axle shafts of a motor vehicle, an axle shaft end play adjuster is threadingly disposed at the end of the axle shaft adjacent the differential pinion shaft. The end play adjuster limits the range of axially inward movement of the axle shaft. A axle shaft end play adjuster assembly includes a shaft supported for rotation about a longitudinal axis having a threaded portion located near an axial end of the shaft to support a washer and a threader adjustment member threadingly engaging the end of the axle shaft adjacent the differential pinion shaft. The adjustment members threaded onto the interior axial end of the axle shaft may respectively engage the associated side gear through a splined interface.

Abstract: A differential gear assembly has a friction clutch for variably restricting differential action. A simple hydraulic piston mechanism is used to amplify the axial force generated by the electric coil and mechanical ball ramp mechanism. The hydraulic system consists of an annular primary piston in contact with the clutch pack, and a multiple set of secondary pistons are attached to the unrestrained ball ramp race. Hydraulic fluid fills the cavity between the primary and secondary pistons. This system provides force multiplication proportional to the surface areas of the respective piston faces.

Abstract: An axle case assembly is provided with a speed sensitive torque coupling mechanism used to transmit torque from the ring gear to a planetary differential assembly. The differential assembly provides torque transfer proportional to the speed difference between the ring gear sub-assembly and a planetary gear set sub-assembly, wherein the invention splits a differential case assembly into two primary pieces and a speed sensitive mechanism is installed between each piece. The mechanism is entirely contained inside an axle differential case assembly. An optional limited slip device may be provided for the differential gears. The torque transmission coupling assembly eliminates the need for a center differential in the transfer case, i.e. an interaxle differential, thereby reducing the driveline complexity and cost without requiring a separate torque coupling in the transfer case or in-line with the driveline.

Abstract: An assembly by which to effect incremental adjustments to the end play, or preloading, to a bearing set. Relatively rotatable first and second thrust rings have contiguously juxtaposed and interacting ramp surfaces. Interposed between the first and second thrust rings is an indexing spring that provides incremental adjustment of the first thrust ring with respect to the second thrust ring. A plurality of indexing pawls formed on the indexing spring interacts with a plurality of indexing teeth formed on one of the thrust rings. The second thrust ring is selectively rotatable with respect to the first thrust ring to effect axial translation of the first thrust ring by virtue of the interaction between said opposed, contiguously juxtaposed ramp surfaces. The indexing pawls preclude reverse relative rotation of the thrust plates.

Abstract: A differential assembly having a preload or biased differential case. A beveled thrust washer is disposed between each side gear and the differential case. The beveled thrust washer induces a preload between the side gear and differential case to help ensure that each differential side gear and output half shaft are running at the same speed as the differential case is rotated. The preload or bias is set to be slightly greater than the difference in drag forces acting on each output half shaft. Thus, when the transfer case is engaged to bring the differential case up to speed, the differential gears will be prevented from spinning and the output half shafts will rotate at the same speed coincident with the vehicle road speed. The preload facilitates more desirable engagement of the wheeled hublocks in front wheel steerable wheel axle assemblies in selectable four-wheel drive trains.

Abstract: A dual ball ramp actuator having a control ring acting with a pressure plates to supply an axial clutch clamping force to a differential clutch assembly where the ball ramp paths follow overlapping eccentric grooves that can be actuated in both the forward and reverse directions. The dual ramp feature doubles the effectiveness and sensitivity when compared to a single ramp system. The overlapping eccentric ball ramps increase (effectively double) the angular travel distance while reducing the ramp angle (in half). The forward and reverse feature provides clutch actuation in both the forward and reverse directions. The dual ramp, 3-piece sandwich construction permits the central control ring to roll up on two sets of balls on each side. This structure doubles the axial travel available to compress a disc pack and lock up the differential with the same ball ramp angle when compared to a single ramp system involving only two ramp plates.

Abstract: A universal differential bearing preload tool includes a pair of opposite cylindrical discs simulating differential bearing cups, a disc spreading device for adjusting a distance between the discs, and a force measuring device associated with the disc spreading device. The opposite cylindrical discs are removably fastened to the preload tool and selected from a plurality of discs having assorted external diameters simulating differential bearing cups of different sizes and manufactures. The bearing preload tool is used for mounting a differential case in a differential housing with a predetermined bearing preload.

Abstract: The device for adjusting an endplay of an axle shaft in a differential assembly includes an axle shaft supported in a differential case for rotation about a longitudinal axis, and an endplay adjustment member threadedly mounted on a terminal shoulder provided at an inboard end of the axle shaft. The axle shaft has external splines adapted to mate with internal splines of a differential side gear and an annular groove located adjacent to the terminal shoulder. The annular groove receives a retainer ring provided to limit an axial displacement of the axle shaft in an outboard direction. The endplay adjustment member is selectively positionable on the terminal shoulder along the axial direction of the axle shaft to variably limit an axial movement of the retainer ring within the annular groove, thus adjusting the axle shaft endplay.

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: An axle assembly employs a simple adjustable connection between the differential case and the housing to adjust the position of the ring gear relative to the pinion gear. A pair of adjustment collars facilitates positioning the differential case to selectively position the ring gear relative to the pinion gear of an input shaft. The adjustment collars threadingly engage the differential case. Bearings are disposed between the adjustment collars and the housing. The adjustment collars are rotated to position the differential case together with the ring gear. The adjustment collars are also provided to adjust the preload of the bearings. A locking collar is employed to lock the adjustment collars once the differential case and ring gear are properly positioned. In an alternate embodiment a single adjustment collar is employed. Shims and spacers are utilized to position the differential case and ring gear and the adjustment collar used to adjust the preload of the bearings.

Abstract: An integrated wheel end system for a vehicle including a clutch adapted to provide driving engagement/disengagement of a wheel to convert between driven and non-driven modes of wheel movement. A vehicle is provided with both 4×2 and 4×4 capabilities and, when 4×4 capability is required, a negative pressure is applied to a vacuum cavity thus causing a piston, shift fork and spline collar to move inboard. The spline collar is splined to the constant velocity joint and as it moves inboard it locks on the spline plate locking the wheelend to the axle shaft. The invention also provides a default 4×4 embodiment, the spline collar is splined to the joint and as the piston fork and spline collar move inboard, they unlock the wheelend from the axle shaft. A selectively activated actuator is provided for moving the clutch member between its driving and non-driving positions.

Abstract: A differential assembly having a limited slip device with a mechanism to adjust the preload of a clutch pack. The differential assembly includes a differential case with pinion and side gears disposed therein. The clutch pack is disposed between at least one of the side gears and the differential case to retard relative rotation there between. An adjustment collar is disposed between the clutch pack and the differential case to adjust the preload of the clutch pack. Elongated slots are formed through the differential case to provide external access to spanner slots formed in the adjustment collar. A tool may be inserted through the elongated slots to engage the spanner slots and selectively rotate the adjustment collar to adjust the preload.

Abstract: A novel arrangement of an electronically controlled limited slip differential assembly including a friction clutch assembly provided within a differential case for selectively restricting differential action. The friction clutch assembly is contained between a separation plate fixed to the differential case and axially spaced from a side gear, and a thrust collar splined to one of axle shafts and movable in axial direction in order to actuate the friction clutch assembly. The friction clutch assembly includes alternating inner friction plates splined to the thrust collar, and outer friction plates non-rotatably coupled to the differential case. The friction clutch assembly is actuated by a selectively controllable actuator including an electrical motor, a reduction gearing and a ball-and-ramp actuator adapted to axially displace the thrust collar in response to rotation of the electrical motor. The differential assembly provides both limited slip and open differential capabilities.

Abstract: An inboard hub lock assembly integrated into a steering knuckle. Teeth are provided on an end of the CV housing and an adjacent flange extending from the wheel hub. A clutch member with corresponding teeth is movable between 1) an outboard position engaging the CV housing teeth and the wheel hub flange teeth, thereby transmitting drive power from a stub shaft to the wheel hub, and 2) an inboard position engaging only the CV housing teeth, thereby permitting the wheel hub to rotate freely relative to the stub shaft. A spring biases the clutch member to a 4×2 mode fail safe position by biasing the clutch member to the inboard non-engaging position.

Abstract: An adjustable mounting assembly for a steerable wheel assembly. A cam member is rotatably disposed within a recess formed in the lower arm of a yoke assembly. An eccentric cylinder of the cam member extends within a vertically oriented slot formed in a ball joint forging which is in turn adjustable secured to the lower arm of the yoke. By simply rotating the cam member, the eccentric cylinder engages the slot and moves the ball joint forging in a horizontal direction to adjust the caster of the wheel assembly. The vertical slot in the ball joint forging prevents vertical movement to facilitate adjustment of the caster without affecting a camber setting, the distance between the upper and lower ball joints, or ball joint pre-loading. Horizontal slots are formed in the lower arm to align with boltholes formed in the ball joint forging to allow the forging to be bolted to the lower arm over a range of horizontal positions. A method of adjusting the camber of the wheel assembly is also disclosed.

Abstract: The drive axles of a motor vehicle differential assembly are secured within the central bores provided in the side gears of the differential assembly by a pair of arcuate retaining element having a rounded cross section which preferably is a piece of bar stock bent to define a 180° half-ring element that is securely held between an arcuate groove formed along the circumference of the axle and a rounded abutment surface provided on the side gear. The arcuate groove and rounded abutment surface reduce stress risers and eliminate the counterbore typically provided in the side gear. Moreover, the pair of retaining elements maximizes the frictional contact by circumscribing the axle by approximately 360°.

Abstract: An adjustable pinion offset in a differential axle assembly. The offset between a pinion gear and shaft relative to a ring gear in the differential axle assembly is adjustable due to an eccentric mounting of the pinion assembly relative to the differential housing containing the ring gear. The pinion shaft is eccentrically mounted within a bore of the differential housing such that a simple rotation of the pinion assembly about the eccentric pilot mounting adjusts the position of the pinion shaft with respect to the ring gear to adjust pinion offset. Once properly positioned, the pinion assembly is secured to the differential housing to maintain the desired position. This invention substantially reduces the noise associated with gear offset error.

Abstract: An assembly to effect adjustments to the end play, or preloading, of a bearing set. The adjusting assembly utilizes a threaded bearing cup body and a correspondingly threaded adjusting ring. The bearing cup body abuts the outer race of the bearing and the adjusting ring is threaded onto the bearing cup body and abuts a fixed or stationary housing surface. The adjusting ring is rotated to adjust bearing preload and provide proper spacing. The bearing cap is then placed to lock the bearing adjusting assembly in place.

Abstract: A novel arrangement of a hydraulic actuator assembly is disclosed. The hydraulic actuator assembly comprises a bi-directional electric motor driving a drive screw. A shaft coupler is threaded onto the drive screw. The shaft coupler is splined to a stationary coupler retainer to prevent rotational movement thereof. The shaft coupler is connected to a hydraulic piston slidably mounted within a pressure chamber by a compression spring. The spring functions both as a damper and as accumulator in a hydraulic system to help stabilize hydraulic pressure. An electrical control system for the hydraulic actuator comprises a high-pressure cutoff switch, a low-pressure cutoff switch, and a control switch. The control switch is adapted for activating the hydraulic actuator assembly and selecting desired operation mode.