Abstract: A method for manufacturing a combined driveshaft tube and yoke assembly includes the initial step of orienting a first component having a first wall thickness and a second component having a second wall thickness to define an overlap region. The first and second components may have the same or different wall thicknesses, may be formed from the same or different materials, and may have the same or different lengths. Portions of the first and second components are deformed to provide the overlap region with a third wall thickness that is the sum of the first wall thickness and the second wall thickness. Lastly, a pair of yoke arms having respective openings therethrough is formed in the overlap region to provide a combined driveshaft tube and yoke assembly. A pair of combined driveshaft tube and yoke assembly can also be manufactured in accordance with this method.

Abstract: A drive axle assembly for motor vehicles, includes a support beam member having a substantially flat, enlarged central plate section and two opposite arm sections, a differential assembly module secured to the central plate section and enclosed into a housing formed by a rear cover and a front cover secured to opposite surfaces of the central plate section. A method for assembling the drive axle assembly comprises the steps of securing the front cover to a front mounting surface of the support beam member, fastening the differential assembly module to the central plate section of the support beam member, and fastening the rear cover to the rear mounting surface of the support beam member.

Abstract: A drive axle assembly for a motor vehicle comprises a support beam member, a differential assembly module secured to the support beam member and a cover member fastened to the support beam member to cover at least a portion the differential assembly module. The cover member includes two spaced access openings with adjustable sealing flange devices for sealing an interior cavity within the cover member between the access openings and corresponding axle shaft members. The sealing flange device is positionally adjustable relative to the cover member. A method for adjusting position of the sealing flange device relative to the cover member comprises the steps of securing the cover member to the axle support member, mounting the sealing flange device to the cover member, adjusting the position of the sealing flange device relative to the cover member and securing the sealing flange device to the cover member.

Abstract: A torque transfer assembly for a motor vehicle comprises a ring gear subassembly and a differential subassembly rotatably supported in said ring gear subassembly, a friction clutch pack for coupling the ring gear subassembly to the differential subassembly, and a hydraulic clutch actuator for selectively frictionally loading the clutch pack. The hydraulic clutch actuator includes a variable pressure relief valve assembly to selectively control the friction clutch pack. The variable pressure relief valve assembly includes a valve closure member, a valve seat complementary to the valve closure member, and a electro-magnetic actuator for engaging the valve closure member and urging thereof against the valve seat with an axial force determined by a magnitude of an electric current supplied to the electro-magnetic actuator so as to selectively vary a release pressure of the pressure relief valve assembly based on the magnitude of the electric current.

Abstract: A slip joint includes a structure that prevents a negative pressure situation from occurring within a sealed lubricant chamber during operation thereof. The slip joint includes a male splined member having a plurality of external splines formed thereon that cooperate with a plurality of internal splines formed on a female splined member. The cooperating splines are disposed within a lubricant chamber defined at one end by a seal assembly and at the other end by a pressure regulator assembly. The pressure regulator assembly includes a housing having an open end that faces toward the lubricant chamber. A pressure plate is disposed within the housing of the pressure regulator assembly and is supported for sliding movement relative thereto. A spring urges the pressure plate toward the open end of the housing and the lubricant chamber.

Abstract: A flange yoke is precisely positioned on a companion flange that, in turn, is supported on a male splined shaft having a pilot that protrudes co-axially therefrom. The companion flange includes a female splined sleeve portion that cooperates with the male splined shaft and a flange portion that has a plurality of apertures formed therethrough. The flange yoke includes a flange portion that has a plurality of apertures formed therethrough that correspond generally in size and location with the plurality of apertures formed through the flange portion of the companion flange and a and a yoke portion. When the flange portion of the flange yoke is disposed adjacent to the flange portion of the companion flange, the apertures formed through the flange portion of the companion flange are axially aligned with the apertures formed through the flange portion of the flange yoke. The flange yoke has a pilot receiver that receives the pilot that protrudes from the splined shaft.

Abstract: The performance of a magnetic pulse forming or welding process is monitored by positioning a deformation member relative to an inductor coil of the apparatus, then energizing the inductor coil to exert a force thereon. The deformation member can be a plastically deformable tube, and the amount of such plastic deformation that occurs when the inductor coil is energized can be measured to determine the magnitude of the force that is generated by the inductor coil. Alternatively, the deformation member can be an elastically deformable body, and the amount of such elastic deformation that occurs when the inductor coil is energized can be measured to determine the magnitude of the force that is generated by the inductor coil.

Abstract: A driveshaft assembly that is axially collapsible in a reliably controlled manner includes a male splined slip yoke that cooperates with a female splined transition member for concurrent rotational movement and for relative axial movement. The transition member is, in turn, secured to a hollow cylindrical driveshaft tube. The transition member has an inner surface that tapers or otherwise extends radially inwardly, and a wedge is supported within the transition member. When a large compressive force is applied to the ends of the driveshaft assembly, the slip yoke causes the wedge to move axially relative to the transition member, thereby causing the transition member and a portion of the hollow cylindrical driveshaft tube to be expanded radially outwardly and creating a weakened region. When the wedge is moved yet axially further relative to the transition member, the driveshaft tube is further deformed in a controlled and consistent, thereby absorbing energy from the collision.

Abstract: A slip joint includes a slip shaft having a plurality of axially extending grooves, and a slip yoke having a plurality of axially extending grooves. The slip yoke is in telescoping engagement with the slip shaft, and the grooves formed in the slip shaft are circumferentially aligned with the grooves formed in the slip yoke. A plurality of torque transmitting balls is disposed in the grooves. A helically shaped cage is positioned radially between the slip shaft and the slip yoke. The cage secures the balls to maintain the balls spaced apart from one another and within the grooves.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: A balance correction device is supported within a hollow article, such as a driveshaft assembly for a vehicular drive train system, to balance the article for rotation. The balance correction device includes a first disc having a first slot provided therein and a second disc having a second slot provided therein. Portions of the first and second slots are axially aligned with one another. An object, such as a ball, is received within the axially aligned portions of the first and second slots. The first and second discs can be positioned relative to one another to position the object relative to the unbalanced article to balance the unbalanced article for rotation.

Abstract: A compound driveshaft assembly includes a first driveshaft section that is connected through a front stub shaft to an inner race of a constant velocity universal joint. The constant velocity universal joint includes a unitary outer race and splined member having an outer race portion that is disposed about the inner race and a splined portion that extends axially rearwardly from the outer race portion. The unitary outer race and splined member is formed from a single piece of material, not from an assembly of two or more separate components. A plurality of balls provide a driving connection between the outer race portion of the unitary outer race and splined member and the inner race. The splined portion of the unitary outer race and splined member is connected for rotation with a rear stub shaft. To accomplish this, the rear stub shaft includes a splined portion that cooperates with the splined portion of the unitary outer race and splined member.

Abstract: A method of manufacturing a tube for a vehicle driveshaft assembly forms a flat sheet of material having a greater thickness than other portions over a portion of its width and along its length, rolling the sheet about a longitudinal axis such that its lateral edges are mutually adjacent, then securing the lateral edges together by seam welding to form a tube. The mass distribution is not uniform because the wall thickness of certain portions of the tube is greater than the wall thickness of other portions of the tube. A tube yoke is machined and the angular location of its overbalance about its longitudinal axis is determined. The tube is secured to the tube yoke such that the angular location of overbalance of the yoke is aligned with the weld seam and diametrically opposite the region of the tube having the greater wall thickness.

Abstract: The differential assembly includes a rotatable differential case, a pair of side gears rotatably mounted within the differential case, and a set of spaced apart differential pinion mate gears rotatably supported by a pinion shaft and drivingly engaging said side gears to allow differential rotation therebetween. A sum of a number of teeth of any one of the side gears and a number of teeth of any one of the pinion mate gears is no greater than nineteen, a difference between the number of teeth of any one of the side gears and the number of teeth of any one of the pinion mate gears is no greater than three, and the number of teeth of any one of the side gears and the number of teeth of any one of the pinion mate gears each is no greater than eleven.

Abstract: A final drive unit for a motor vehicle includes a carrier housing integrally formed with a final drive housing and provided to store a lubricating oil therein, a pinion drive shaft rotatably supported within the final drive housing by a pair of bearings, an oil supply passage formed integrally with the final drive housing for lubricating the bearings and having a supply opening in communication with a cavity in the carrier housing, and a baffle member mounted within the carrier housing adjacent to the supply opening of the oil supply passage. The baffle member includes a baffle wall provided to cover a lower portion of the oil supply passage for maintaining a portion of the lubrication oil within the oil supply passage so as to permit the lubricating oil to adequately lubricate the bearings even when the motor vehicle is tilted to a maximum angle of inclination.

Abstract: A fluid coupling employing a viscous fluid to produce a limited slip differential assembly. The fluid coupling is disposed within a differential casing along with a pair of side gears. The fluid coupling includes a first impeller provided with a first set of vanes and drivingly coupled to one of the side gears, a second impeller provided with a second set of vanes and drivingly coupled to the differential casing so that the first set of vanes is facing the second set of vanes, and a viscous fluid disposed between the first and second sets of vanes.

Abstract: A center bearing assembly rotatably supports an intermediate portion of a vehicle driveshaft assembly during use. The center bearing assembly includes a rigid bracket that is secured to a support surface of the vehicle, a support member that is supported within the rigid bracket, and an annular bearing that is supported within the support member for rotatably supporting the intermediate portion of the vehicle driveshaft assembly. The support member is formed from a resilient material and has a cavity formed therein. A sponge is disposed within the cavity formed in the support member. The sponge may be formed from any material that is capable of absorbing or otherwise retaining a quantity of a rheological fluid therein. A control circuit is provided for selectively generating and applying an energy field to the Theological fluid contained within the sponge and thereby varying the resistance to flow or shear thereof. As a result, the vibration dampening characteristics of the support member can be varied.

Abstract: A method for determining a thickness of a shim for setting up a predetermined preload of a bearing assembly that rotatably supports a shaft within a housing. The bearing assembly includes front and rear tapered roller bearings. The shim is disposed between a bearing supporting shoulder of the shaft and an inner cone of the rear bearing. The method comprises the steps of: measuring a distance X from an end face of the shaft to the bearing supporting shoulder thereof; measuring a height B of the inner cone; mounting the shaft within the housing; applying a load to the inner cone of the rear bearing corresponding to a predetermined preload; measuring a distance XL from the end face of the shaft to the inner cone of the rear bearing; and determining the thickness W of the shim in accordance with the following equation: W=X?XL?B.

Abstract: An active differential assembly provides speed control of an associated output shaft. A differential case is rotatably mounted within a housing to drive a pair of output shafts extending from the differential case in opposite directions for distributing driving force from the engine to wheels. A pair of planetary gear sets are one each disposed about a corresponding output shaft and includes a planetary ring gear, a sun gear fixed to the output shaft, and a planetary carrier rotatably supporting a plurality of planet gears operatively coupling the planetary ring gear with the sun gear. A brake mechanism is disposed between the planetary ring gear and the housing for selectively braking the planetary ring gear to thereby cause an associated increase in speed of the axle shaft.

Abstract: A process for balancing a vehicular driveline including a propeller shaft and an input shaft of a vehicle axle interconnected by a universal joint. First, the vehicle propeller shaft is balanced to a predetermined residual imbalance having an imbalance vector angle of 0° or 180° which lies inline with open set of cardan joint trunnions. The corrected residual imbalance is then visually marked. Next, the input shaft is balanced to a predetermined residual imbalance having an imbalance vector angle of 0° or 180° which lies inline with cross-holes in yoke ears. Again, the corrected residual imbalance on the input shaft is then visually marked. During the assembly of the vehicle, the assembly line operator couples the propeller shaft to the input shaft through a cardan joint cross by aligning the marks on the propeller shaft and the input shaft so that the marks are located opposite to each other.